Toshiba RAS-10EAVP-E, RAS-B16EKVP-E, RAS-13EAVP-E, RAS-B13EKVP-E, RAS-16EAVP-E User Manual

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SERVICE MANUAL

AIR-CONDITIONER

FILE NO. A04-013

SPLIT TYPE

RAS-B10EKVP-E RAS-B13EKVP-E RAS-B16EKVP-E

RAS-10EAVP-E RAS-13EAVP-E RAS-16EAVP-E

CONTENTS

1. SAFETY PRECAUTIONS............................................................................ 3

2. SPECIFICATIONS ........................................................................................ 5

3. REFRIGERANT R410A............................................................................... 7

4. CONSTRUCTION VIEWS ......................................................................... 15

5. WIRING DIAGRAM..................................................................................... 17

6. SPECIFICATIONS OF ELECTRICAL PARTS .......................................... 18

7. REFRIGERANT CYCLE DIAGRAM ......................................................... 19

8. CONTROL BLOCK DIAGRAM ................................................................. 22

9. OPERATION DESCRIPTION .................................................................... 24

10. INSTALLATION PROCEDURE ............................................................... 48

11. HO W TO DIAGNOSE THE TR OUBLE..................................................... 62

12. HOW TO REPLACE THE MAIN PARTS.................................................. 84

13. EXPLODED VIEWS AND PARTS LIST................................................ 104

14. APPENDIX ............................................................................... Appendix-1

– 2 –

1. SAFETY PRECAUTIONS

For general public use

Power supply cord of outdoor unit shall be more than 1.5 mm2 (H07RN-F or 245IEC66) polychloroprene sheathed flexible cord.

• Read this “SAFETY PRECAUTIONS” carefully before servicing.

• The precautions described below include the important items regarding safety. Observe them without fail.

• After the servicing work, perform a trial operation to check for any problem.

• Turn off the main power supply switch (or breaker) before the unit maintenance.

CAUTION

New Refrigerant Air Conditioner Installation

• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY OZONE LAYER.

R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the working pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. Accompanied with the adoption of the new refrigerant, the refrigeration machine oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigeration machine oil does not enter into the new type refrigerant R410A air conditioner circuit. To prevent mixing of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging port on main unit and installation tools are different from those used for the conventional refrigerant units. Accordingly, special tools are required for the new refrigerant (R410A) units. For connecting pipes, use new and clean piping materials with high pressure fittings made for R410A only , so that w ater and/or dust does not enter . Moreo v er, do not use the existing piping because there are some problems with pressure fittings and possible impurities in existing pipi

ng.

CAUTION

TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY

This appliance must be connected to the main power supply by a circuit breaker or a switch with a contact separation of at least 3 mm.

The installation fuse (25A D type ) must be used for the power supply line of this air conditioner

DANGER

• Ask an authorized dealer or qualified installation professional to install/maintain the air conditioner.

Inappropriate servicing may result in water leakage, electric shock or fire.

• TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL PO WER

SWITCHES ARE OFF. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

DANGER: HIGH VOLTAGE

The high voltage circuit is incorporated. Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by ha

• CORRECTLY CONNECT THE CONNECTING CABLE. IF THE CONNECTING CABLE IS INCORRECTLY CONNECTED,

ELECTRIC PARTS MAY BE DAMAGED.

• CHECK THAT THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE SERVICE AND INSTALLATION.

FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

• DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE TO FOLLOW THIS

INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.

• TO PREVENT THE INDOOR UNIT FROM OVERHEATING AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL

AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT REGISTORS, FURNACE, STOVES, ETC.

• WHEN MOVING THE AIR-CONDITIONER FOR INSTALLATION IN ANOTHER PLACE, BE VERY CAREFUL NOT TO

ALLOW THE SPECIFIED REFRIGERANT (R410A) TO BECOME MIXED WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CIRCUIT. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CIRCUIT WILL BECOME ABNORMALLY HIGH AND IT MAY RESULT IN THE PIPE BURSTING AND POSSIBLE PERSONNEL INJURIES.

• IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE SERVICE WORK AND THE

INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED, SUCH AS BY FIRE, GENERATION OF POISONOUS GAS MAY RESULT

nd.

– 3 –

WARNING

• Never modify this unit by removing any of the safety guards or by-pass any of the safety interlock switches.

• Do not install in a place which cannot bear the weight of the unit. Personal injury and property damage can result if the unit falls.

• After the installation work, confirm that refrigerant gas does not leak. If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas may generate.

• The electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make

sure the air conditioner uses an exclusive circuit.

An insufficient circuit capacity or inappropriate installation may cause fire.

• When wiring, use the specified cables and connect the terminals securely to prevent external forces applied to the

cable from affecting the terminals.

• Be sure to provide grounding. Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.

• Conform to the regulations of the local electric company when wiring the power supply. Inappropriate grounding may cause electric shoc

CAUTION

• Exposure of unit to water or other moisture before installation may result in an electrical short. Do not store in a wet basement or expose to rain or water.

• Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify the noise level of the unit or where noise or discharged air might disturb neighbors.

• To avoid personal injury, be careful when handling parts with sharp edges.

• Perform the specified installation work to guard against an earthquake. If the air conditioner is not installed appropriately, accidents may occur due to the falling

unit.

For Reference:

If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, drainage of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan.

It is recommended to procure an anti freeze heater locally for a safety installation of the air conditioner. For details, contact the dealer.

– 4 –

2. SPECIFICATIONS

2-1. Specifications

RAS-B10EKVP-E/RAS-10EA VP-E, RAS-B13EKVP-E/RAS-13EAVP-E, RAS-B16EKVP-E/RAS-16EAVP-E

Un it mo d e l

Cooling capacity (kW) 2.5 3.5 4.5 Cooling capacity range (kW) 0.5–3.5 0.6–4.5 0.8-5.0 Heating capacity (kW) 3.2 4.2 5.5 Heating capacity range (kW) 0.6–5.8 0.6–6.6 0.8-7.8 Power supply 1Ph/50Hz/220–240 V, 1Ph/60Hz/220 V

Electric characteristics

COP (Cooling/Heating) 4.55/4.51 3.80/4.31 3.26/3.64

Operating noise

Indoor unit

Outdoor unit

Piping connection

connection

Accessory

• The specifications may be subject to change without notice for purpose of improvement.

Indoor Outdoor

Indoor

Outdoor

Indoor

Outdoor (Cooling/Heating) (dB•A) 46/47 48/50 49/50 Un it mo d e l Dimension

Net weight (kg) 9 9 9 Fan motor output (W) 30 30 30 Air flow rate (Cooling/Heating) (m³/h) 550/610 560/640 640/660 Un it mo d e l Dimension

Net weight (kg) 35 37 37 Com p res so r

Fan motor output (W) 43 43 43 Air flow rate (Cooling/Heating) (m³/h) 2150/2150 2410/2410 24 10/2410 Type Flare connection Flare connection Flare connection

Maximum length (m) 25 25 25 Maximum chargeless length (m) 15 15 15 Maximum height difference (m) 10 10 10 Name o f refrigerant R410 A R410A R410A Refrigerant Weight (kg) 0.82 0.96 0.96 Power supply 3 Wires : includes ear th (O utdoor) Wiring Interconnection 4 Wires : includes ear th

Indoor unit

Outdoor unit

Operation mode Running current (A) 0.15 0.15 0.15 0.15 0.15 0.15 Power consumption (W) 30 30 30 30 30 30 Power factor (%) 87 87 87 87 87 87 Operation mode Running current (A) 2.48/2.37/2.26 3.25/3.10/2.96 4.25/4.06/3.89 4.52/4.31/4.13 6.45/6.17/5.90 7.07/6.76/6.47 Power consumption (W) 520 680 890 945 1350 14 80 Power factor (%) 95 95 95 95 95 95 Starting current (A) 3.40/3.25/3.11 4.67/4.46/4.28 7.22/6.91/6.62

High (Cooling/Heating) (dB•A) 42/43 43/44 45/45 Medium (Cooling/Heating) (dB•A) 33/34 34/35 36/36 Low (Cooling/Heating) (dB•A) 27/27 27/27 29/29

Height (mm) 250 250 250 Width (mm) 790 790 790 Depth (mm) 215 215 215

Height (mm) 550 550 550 Width (mm) 780 780 780 Depth (mm) 290 290 290

Motor output (W) 750 750 750 Type Twin ro tary type w ith D C-inverte r va r iable s pe e d co n trol Model DA111A1F-20F1 DA111A1F-20F1 DA111A1F-20F1

Liquid side Ø6.35 Ø6.35 Ø6.35 Indoor unit Gas side Ø9.52 Ø9.52 Ø12.7 Liquid side Ø6.35 Ø6.35 Ø6.35 Outdoor unit Gas side Ø9.52 Ø9.52 Ø 12 .7

Indoor (Cooling/Heating) (°C) 21–32/0–28 21–32/0–28 21–32/0–28 Usable temperature range Outdoor (Cooling/Heating) (°C) 5–43/–15–24 5–43/–15–24 5–43/–15–24 Installation plate 1 1 1 Wireles s remote c on tro ller 1 1 1 Batteries 2 2 2 Remote c ontroller holder 1 1 1 Zeolite-plus filter 1 1 1 Mounting screw 6 (Ø4 x 25L) 6 (Ø4 x 25L) 6 (Ø4 x 25L) Remote c ontroller holder

mounting screw Plasma Pure filter 1 1 1 Installation m anu al 1 1 1 Owner’s manual 1 1 1 Drain nipple 1 1 1 Water-proof rubber cap 2 2 2

2 (Ø3.1 x 16L) 2 (Ø 3.1 x 16L) 2 (Ø3.1 x 16L)

RAS-B10EKVP-E RAS-B13EKVP-E RAS-B16EKVP-E

RAS-10EAVP-E RAS-13EAVP-E RAS-16EAVP-E

Cooling Heating Cooling Heating Cooling Heating

RAS-B10EKVP-E

RAS-10EAVP-E

RAS-B13EKVP-E

RAS-13EAVP-E

RAS-B16EKVP-E

RAS-16EAVP-E

– 5 –

2-2. Operation Characteristic Curve

10 10

RAS-B10EKVP-E RAS-B13EKVP-E

RAS-B16EKVP-E

Current (A)

0 20406080 120100

• Conditions Indoor : DB 27˚C/WB 19˚C Outdoor : DB 35˚C Air flow : High Pipe length : 7.5m Voltage : 230V

Current (A)

0 20 40 60 80 120140 140100

Compressor speed (rps)

2-3. Capacity Variation Ratio According to Temperature

RAS-B10EKVP-E RAS-B13EKVP-E RAS-B16EKVP-E

• Conditions Indoor : DB 20˚C Outdoor : DB 7˚C/WB 6˚C Air flow : High Pipe length : 7.5m Voltage : 230V

Compressor speed (rps)

110

100

RAS-B10EKVP-E

Capacity ratio (%)

32 34 36 38 40 4233 35 37 39 41 43 44 45

RAS-B13EKVP-E RAS-B16EKVP-E

• Conditions Indoor : DB27˚C/WB19˚C Indoor air flow : High Pipe length : 7.5m

Outdoor temp. (˚C)

Capacity ratio : 100% = 2.5 kW (RAS-B10EKVP-E)

Capacity ratio : 100% = 3.5 kW (RAS-B13EKVP-E)

Capacity ratio : 100% = 4.5 kW (RAS-B16EKVP-E)

120

100

RAS-B10EKVP-E RAS-B13EKVP-E RAS-B16EKVP-E

Capacity ratio (%)

0 –15 –10 –5 0 5 10

• Conditions Indoor : DB 20˚C Indoor air flow : High Pipe length : 7.5m

Outdoor temp. (˚C)

– 6 –

3. REFRIGERANT R410A

This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer.

The working pressure of the new refrigerant R410A is

1.6 times higher than conventional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time.

The next section describes the precautions for air conditioner using the new refrigerant. Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work.

3-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.

(1 ) Never use refrigerant other than R410A in an air

conditioner which is designed to operate with R410A.

If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture.

(2 ) Confirm the used refrigerant name, and use tools

and materials exclusive for the refrigerant R410A.

The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air conditioner using R410A as refrigerant. To prevent mischarging, the diameter of the service port differs from that of R22.

(3 ) If a refrigeration gas leakage occurs during

installation/servicing, be sure to ventilate fully. If the refrigerant gas comes into contact with fire,

a poisonous gas may occur .

(4 ) When installing or removing an air conditioner , do

not allow air or moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused.

(5) After completion of installation work, check to

make sure that there is no refrigeration gas leakage.

If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur.

(6) When an air conditioning system charged with a

large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result.

(7) Be sure to carry out installation or removal

according to the installation manual. Improper installation may cause refrigeration

trouble, water leakage, electric shock, fire, etc.

(8 ) Unauthorized modifications to the air conditioner

may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician.

Improper repair’s ma y result in water leakage , electric shock and fire, etc.

3-2. Refrigerant Piping Installation

3-2-1. Piping Materials and Joints Used

For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.

(1 ) Copper Pipes

It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface).

Otherwise, the expansion valve or capillary tube may become blocked with contaminants.

As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A are as shown in Tab le 3-2-1. Never use copper pipes thinner than 0.8 mm even when it is available on the market.

– 7 –

T ab le 3-2-1 Thicknesses of annealed copper pipes

Thickness (mm)

Nominal diameter

1/4 3/8 1/2 5/8

(2) Joints

For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.

a) Flare Joints

Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used.

Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 3-2-3 to 3-26 below .

Outer diameter (mm)

6.35

9.52

12.70

15.88

R410A R22

0.80 0.80

1.00 1.00

b) Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm.

Thicknesses of socket joints are as shown in T able 3-2-2.

T ab le 3-2-2 Minim um thicknesses of soc ket joints

Nominal diameter

1/4 3/8 1/2 5/8

Reference outer diameter of

copper pipe jointed (mm)

3-2-2. Processing of Piping Materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil other than lubricating oils used in the installed air conditioner is used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover .

Minimum joint thickness

(mm)

6.35

9.52

12.70

15.88

(1 ) Flare Processing Procedures and Precautions

a) Cutting the Pipe

By means of a pipe cutter, slo wly cut the pipe so that it is not deformed.

b) Removing Burrs and Chips

If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and clean the cut surface before installation.

c) Insertion of Flare Nut

0.50

0.60

0.70

0.80

– 8 –

d) Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned.

By means of the clamp bar, perform the flare processing correctly.

Use either a flare tool for R410A or conventional flare tool.

Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

T able 3-2-3 Dimensions related to flare pr ocessing f or R410A

ØD

Fig. 3-2-1 Flare processing dimensions

Nominal

diameter

1/4 3/8 1/2 5/8

Nominal

diameter

1/4 3/8

Outer

diameter

(mm)

6.35

9.52

12.70

15.88

Thickness

(mm)

0.8

1.0

Flare tool for R410A

clutch type

0 to 0.5 1.0 to 1.5 1.5 to 2.0 0 to 0.5 1.0 to 1.5 1.5 to 2.0 0 to 0.5 1.0 to 1.5 2.0 to 2.5 0 to 0.5 1.0 to 1.5 2.0 to 2.5

T able 3-2-4 Dimensions related to flare pr ocessing f or R22

Outer

diameter

(mm)

6.35

9.52

Thickness

(mm)

0.8

Flare tool for R410A

clutch type

0 to 0.5 0.5 to 1.0 1.0 to 1.5 0 to 0.5 0.5 to 1.0 1.0 to 1.5

A (mm)

Conventional flare tool

Clutch type Wing nut type

A (mm)

Conventional flare tool

Clutch type Wing nut type

1/2 5/8

Nominal

diameter

1/4 3/8 1/2 5/8

12.70

15.88

T ab le 3-2-5 Flare and flare nut dimensions f or R410A

Outer

diameter

(mm)

6.35

9.52

12.70

15.88

0.8

1.0

Thickness

(mm)

0.8

1.0

0 to 0.5 0.5 to 1.0 1.5 to 2.0 0 to 0.5 0.5 to 1.0 1.5 to 2.0

Dimension (mm)

ABCD

9.1 9.2 6.5 13

13.2 13.5 9.7 20

16.6 16.0 12.9 23

19.7 19.0 16.0 25

– 9 –

Flare nut

width

(mm)

17 22 26 29

T ab le 3-2-6 Flare and flare nut dimensions f or R22

Nominal

diameter

1/4 3/8 1/2 5/8 3/4

Outer

diameter

(mm)

6.35

9.52

12.70

15.88

19.05

Thickness

(mm)

0.8

1.0

45˚ to 46˚

B A

Dimension (mm)

ABCD

9.0 9.2 6.5 13

13.0 13.5 9.7 20

16.2 16.0 12.9 20

19.7 19.0 16.0 23

23.3 24.0 19.2 34

Flare nut

width

(mm)

17 22 24 27 36

Fig. 3-2-2 Relations between flare nut and flare seal surface

(2 ) Flare Connecting Procedures and Precautions

a) Make sure that the flare and union portions do

not have any scar or dust, etc.

b) Correctly align the processed flare surface

with the union axis.

c) Tighten the flare with designated torque by

means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur .

T able 3-2-7 Tightening torque of flare f or R410A [Reference v alues]

Nominal

diameter

Outer

diameter

(mm)

Tightening torque

N•m (kgf•cm)

43˚ to 45˚

When it is strong, the flare nut may crack and may be made non-remova ble . When choosing the tightening torque, comply with values designated by manufacturers. Table 3-2-7 shows reference values.

NOTE :

When applying oil to the flare surface, be sure to use oil designated by the manufacturer. If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.

Tightening torque of torque

wrenches available on the market

N•m (kgf•cm)

1/4 3/8 1/2 5/8

6.35

9.52

12.70

15.88

14 to 18 (140 to 180) 33 to 42 (330 to 420) 50 to 62 (500 to 620) 63 to 77 (630 to 770)

– 10 –

16 (160), 18 (180)

42 (420) 55 (550) 65 (650)

3-3. T ools

3-3-1. Required T ools

The service port diameter of packed valv e of the outdoor unit in the air conditioner using R410A is changed to prevent mixing of other refrigerant. To reinf orce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened.

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.

(1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22)) (2) Tools exclusive for R410A, but can be also used f or conventional refrigerant (R22) (3 ) Tools commonly used for R410A and f or con v entional refrigerant (R22) The table below shows the tools exclusive for R410A and their interchangeability.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

Conventional air

conditioner installation

Whether new equipment can be used with conventional refrigerant

(Note 1)

No.

3 4

5 6

7 8

Used tool

Flare tool Copper pipe gauge for

adjusting projection margin

Torque wrench (For Ø12.7)

Gauge manifold Charge hose

Vacuum pump adapter Electronic balance for

refrigerant charging Refrigerant cylinder Leakage detector Charging cylinder

Usage

Pipe flaring Flaring by

conventional flare tool

Connection of flare nut

Evacuating, refrigerant charge, run check, etc.

Vacuum evacuating Refrigerant charge

Refrigerant charge Gas leakage check Refrigerant charge

Yes

Yes Yes

R410A

Whether conventional equipment can be used

(Note 1)

air conditioner installation

Existence of new equipment for R410A

(Note 2)

X X

X X X

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection

margin is necessary . For this adjustment, a copper pipe gauge, etc. are necessary.

(Note 2) Charging cylinder for R410A is being currently developed.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as the general tools.

(1) Vacuum pump

Use vacuum pump by

attaching vacuum pump adapter. (2) Torque wrench (For Ø6.35, Ø9.52) (3) Pipe cutter (4) Reamer

(5) Pipe bender (6) Level vial (7) Screwdriver (+, –) (8) Spanner or Monkey wrench (9) Hole core drill (Ø65)

(10) Hexagon wrench

(Opposite side 4mm)

(11) Tape measure (12) Metal saw

Also prepare the following equipments for other installation method and run check.

(1) Clamp meter (2) Thermometer

(3) Insulation resistance tester (4) Electroscope

– 11 –

3-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps.

Recover the refrigerant, and check no refrigerant remains in the equipment.

Connect the charge hose to packed valve service port at the outdoor unit’s gas side.

Connect the charge hose to the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

When the compound gauge’s pointer has indicated –0.1 Mpa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauge’s pointer does not return.

Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge liquid refrigerant.

Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pump’s power switch. Then, evacuating the refrigerant in the cycle.

(For refrigerant charging, see the figure below.)

(1 ) Never charge refrigerant exceeding the specified amount. (2) If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode. (3 ) Do not carry out additional charging.

When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury .

(INDOOR unit)

(Liquid side)

(OUTDOOR unit)

Opened

Refrigerant cylinder

(With siphon pipe)

Check valve

Open/Close valve

for charging

Electronic balance for refrigerant charging

Fig. 3-4-1 Configuration of refrigerant charging

(Gas side)

Closed

Service port

– 12 –

(1) Be sure to make setting so that liquid can be charged. (2 ) When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.

It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.

[ Cylinder with siphon ] [ Cylinder without siphon ]

Gauge manifold

OUTDOOR unit

Refrigerant

cylinder

Gauge manifold

OUTDOOR unit

cylinder

Refrigerant

Electronic

balance

R410A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

3-5. Brazing of Pipes

3-5-1. Materi a ls f or B r az i ng

(1) Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper. It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.

Electronic

balance

Siphon

Fig. 3-4-2

(1) Phosphor bronze brazing filler tends to react

with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

(2 ) When performing brazing again at time of

servicing, use the same type of brazing filler.

(2) Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally used to join copper or copper alloy.

(3 ) Low temperature brazing filler

Low temperature brazing filler is generally called solder, and is an alloy of tin and lead. Since it is weak in adhesive strength, do not use it for refrigerant pipes.

3-5-2. Flux

(1 ) Reason why flux is necessary

• By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler.

• In the brazing process, it prevents the metal surface from being oxidized.

• By reducing the brazing filler’s surface tension, the brazing filler adheres better to the treated metal.

– 13 –

(2 ) Characteristics required for flux

Nitrogen gas

cylinder

Pipe

Flow meter

Stop valve

From Nitrogen cylinder

Nitrogen gas

Rubber plug

• Activated temperature of flux coincides with the brazing temperature.

• Due to a wide effective temperature range, flux is hard to carbonize.

• It is easy to remove slag after brazing.

• The corrosive action to the treated metal and brazing filler is minimum.

• It excels in coating performance and is harmless to the human body.

As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc.

(3 ) T ypes of flux

• Noncorrosive flux

Generally, it is a compound of borax and boric acid. It is effective in case where the brazing temperature is higher than 800°C.

• Activated flux

Most of fluxes generally used for silver brazing are this type. It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

(4) Piping materials for brazing and used brazing

filler/flux

3-5-3. Brazing

As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified.

In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N2) flow.

Never use gas other than Nitrogen gas.

(1 ) Brazing method to prevent oxidation

1) Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder.

2) Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.

3) Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

4) When the Nitrogen gas is flowing, be sure to keep the piping end open.

5) Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m3/Hr or 0.02 MPa (0.2kgf/cm2) by means of the reducing valve.

6) After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7) Remove the flux completely after brazing.

Copper - Copper

(1) Do not enter flux into the refrigeration cycle. (2) When chlorine contained in the flux remains

(3) When adding water to the flux, use water

(4) Remove the flux after brazing.

Piping

material

Used brazing Used

filler flux

Phosphor copper Do not use

Copper - Iron

Iron - Iron

Silver Paste flux Silver Vapor flux

within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine.

which does not contain chlorine (e.g. distilled water or ion-exchange water).

Fig. 3-5-1 Prevention of oxidation during brazing

– 14 –

4-1. Indoor Unit

RAS-B10EKVP-E RAS-B13EKVP-E RAS-B16EKVP-E

4. CONSTRUCTION VIEWS

– 15 –

Parts name of remote control WH-H03JE

4-2. Outdoor Unit

RAS-10EA VP-E, RAS-13EA VP-E, RAS-16EAVP-E

– 16 –

5. WIRING DIAGRAM

5-1. Outdoor Unit

RAS-10EA VP-E, RAS-13EA VP-E, RAS-16EAVP-E

5-2. Indoor Unit

RAS-B10EKVP-E, RAS-B13EKVP-E, RAS-B16EKVP-E

1 2 3 4 5 6

FUSE

F01

AC 250V

T3.15A

CN08 (WHI)

BLK

1 2 3 4 5 6

21 43

High-voltage

Power supply

Ion electrode

BLK BLK

HEAT EXCHANGER

SENSOR (TC)

BLK BLK

THERMO SENSOR

(TA)

CN100

(WHI)

BLU

10 10

WHI

Wireless Unit Assembly

MCC-899

1 2 3 4 1 2 3 4

RED

BRW

1 2 3 4 1 2 3 4

CN01

(BLU)

121

CN03

(WHI)

121

CN13

(WHI)

9 8 7 6 5 4 3 2 1

CN33 (WHI)

9 8 7 6 5 4 3 2

MAIN P.C. BOARD

(MCC-5020)

BLK

BRW

Electrode

Air purifier

TNR

INDOOR

TERMINAL

BLOCK

CN22

LINE

FILTER

BLK WHI

3 1

CN23

DB01

RED

exchanger

GRN & YEL

CN21

DC5V

DC12V

Heat

CN34

(RED)

CN07 (WHI)

CIRCUIT

POWER SUPPLY

Identification

RED WHI BLK BLU BRW ORN PUR YEL GRY PNK GRN& YEL

BRW

121

BLU

CN10 (WHI)

RED

BLK

WHI

YEL

BLU

WHI

YEL

LOUVER MOTOR

Color

RED

WHITE

BLACK

BLUE

BROWN

ORANGE

PURPUL

YELLOW

GRAY

PINK

GREEN&

YELLOW

Micro SW

FAN MOTOR

DC MOTOR

– 17 –

6. SPECIFICATIONS OF ELECTRICAL PARTS

6-1. Indoor Unit

RAS-B10EKVP-E, RAS-B13EKVP-E, RAS-B16EKVP-E

No.

Fan motor (for indoor)

Room temp. sensor

(TA-sensor)

Heat exchanger temp. sensor

(TC-sensor)

Louver motor

Parts name

Type

MF-280-30-5

( – )

MP24GA

6-2. Outdoor Unit

RAS-10EA VP-E, RAS-13EA VP-E, RAS-16EAVP-E

No.

Reactor

Outdoor fan motor

Suction temp. sensor

(TS sensor)

Parts name

Model name

CH-57

ICF-140-43-4

(Inverter attached)

Specifications

DC280–340V , 30W

10kΩ at 25°C

Output (Rated) 1W , 16poles, 1phase DC12V

Rating

L=10mH, 16A x 2

DC140V , 43W

10kΩ (25°C)

Discharge temp. sensor

(TD sensor)

Outside air temp. sensor

(TO sensor)

Heat exchanger temp. sensor

(TE sensor)

Terminal block (6P)

Compressor

Coil for PMV

Coil for 4-way valve

(Inverter attached)

——

DA111A1F-20F1

CAM-MD12TF

VHV

62kΩ (20°C)

10kΩ (25°C)

20A, AC250V

3-phases 4-poles 750W

DC12V

AC220-240V

– 18 –

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

RAS-B10EKVP-E/RAS-10EAVP-E

INDOOR UNIT

Indoor heat

exchanger

Temp. measurement

Pressure measurement Gauge attaching port

Vacuum pump connecting port Deoxidized copper pipe

Outer dia. : 9.52mm Thickness : 0.8mm

4-way valve (STF-0108Z)

Muffler

Compressor DA111A1F-20F1

Outdoor heat

exchanger

Cross flow fan

Deoxidized copper pipe Outer dia. : 6.35mm Thickness : 0.8mm

Sectional shape of heat insulator

Allowable height

difference : 10m

Strainer

Pulse motor valve at liquid side (CAM-B22YGTF-2)

Strainer

Max. : 25m Chargeless : 15m Charge : 20g/m (16 to 25m)

Allowable pipe length

Temp. measurement

Propeller fan

OUTDOOR UNIT

NOTE :

Refrigerant amount : 0.82kg

Gas leak check position Refrigerant flow (Cooling) Refrigerant flow (Heating)

NOTE :

• The maximum pipe length of this air conditioner is 25 m. When the pipe length exceeds 15m, the additional charging of refrigerant, 20g per 1m for the part of pipe exceeded 15m is required. (Max. 200g)

– 19 –

RAS-B13EKVP-E/RAS-13EAVP-E RAS-B16EKVP-E/RAS-16EAVP-E

INDOOR UNIT

Indoor heat

exchanger

Temp. measurement

Pressure measurement Gauge attaching port

Vacuum pump connecting port

Deoxidized copper pipe

Outer dia. : 9.52mm(13),

12.7mm(16)

Thickness : 0.8mm

4-way valve (STF-0108Z)

Muffler

Compressor DA111A1F-20F1

Outdoor heat

exchanger

Cross flow fan

Deoxidized copper pipe Outer dia. : 6.35mm Thickness : 0.8mm

Sectional shape of heat insulator

Split capillary

Ø1.2 x 80

Allowable height

difference : 10m

Strainer

Pulse motor valve at liquid side (CAM-B22YGTF-2)

Max. : 25m Chargeless : 15m Charge : 20g/m (16 to 25m)

Allowable pipe length

Temp. measurement

Propeller fan

OUTDOOR UNIT

Ø1.2 x 80

NOTE :

Refrigerant amount : 0.96kg

Gas leak check position Refrigerant flow (Cooling) Refrigerant flow (Heating)

NOTE :

– 20 –

7-2. Operation Data

Temperature

condition (°C)

Indoor Outdoor

27/19 35/–

Temperature

condition (°C)

Indoor Outdoor

20/– 7/6

Model

name RAS-

B10EKVP-E B13EKVP-E B16EKVP-E

Model

name RAS-

B10EKVP-E B13EKVP-E B16EKVP-E

Standard pressure

P (MPa)

0.9 to 1.1

0.8 to 1.0

0.7 to 0.9

Standard pressure

P (MPa)

2.2 to 2.4

2.5 to 2.7

2.8 to 3.0

Heat exchanger

pipe temp.

T1 (°C) T2 (°C)

13 to 15 42 to 44 11 to 14 42 to 45

8 to 11 43 to 47

Heat exchanger

pipe temp.

T1 (°C) T2 (°C)

37 to 39 0 to 3 42 to 45 0 to 2 48 to 49 0 to 2

Indoor fan

mode

High High High

Indoor fan

mode

High High High

Outdoor fan

mode

High High High

Outdoor fan

mode

High High High

Compressor

revolution

(rps)

37 59 82

Compressor

revolution

(rps)

54 65 86

NOTES :

(1 ) Measure surface temperature of heat exchanger pipe around center of heat exchanger path U bent.

(Thermistor themometer)

(2 ) Connecting piping condition : 7.5 m

– 21 –

8. CONTROL BLOCK DIAGRAM

8-1. Indoor Unit

RAS-B10EKVP-E, RAS-B13EKVP-E, RAS-B16EKVP-E

Heat Exchanger Sensor(Tc)

Room Temperature Sensor(Ta)

Infrared Rays Signal Receiver

and Indication

Initializing Circuit

Clock Frequency

Oscillator Circuit

Power Supply

Circuit

Converter

(D.C circuit)

Noise Filter

M.C.U

Functions

• Cold draft preventing Function

• 3-minute Delay at Restart for Compressor

• Fan Motor Starting Control

• Processing (Temperature Processing)

• Timer

• Serial Signal Communication

• Clean Function

Serial Signal Transmitter/Receiver

Indoor Unit Control Unit

Louver

Motor

Louver Motor Drive Control

Indoor Fan

Motor Control

Indoor

Fan Motor

Air purifier

unit

Micro Switch

From Outdoor Unit

220-240V/50Hz

220V/60Hz

REMOTE CONTROLLER

Serial Signal Communication

(Operation Command and Information)

Remote Controller

Operation (START/STOP)

Operation Mode Selection

AUTO, COOL, DRY, HEAT

Thermo. Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver AUTO Swing

Louver Direction Setting

ECO

Hi-POWER

Infrared Rays, 36.7kHz

– 22 –

Air Purifier

SLEEP

8-2. Outdoor Unit (Inverter Assembl y)

RAS-10EA VP-E, RAS-13EA VP-E, RAS-16EKVP-E

detect

Current

circuit

Gate drive

detect

Current

Outdoor

Fan motor

Inverter

(DC → AC)

Compressor

P.M.V : Pulse Motor Valve

M.C.U : Micro Control Unit

MICRO-COMPUTER BLOCK DIAGRAM

M.C.U

MCC5009 (P.C.B) OUTDOOR UNIT

• PWM synthesis function

• Input current release control

circuit

Indoor unit

send/receive

circuit

Gate drive

• IGBT over-current detect control

• Outdoor fan control

• High power factor correction control

• Inverter output frequency control

• A/D converter function

• P.M.V. control

• Discharge temp. control

• 4-way valve control

• Signal communication to indoor unit

4MHz

Clock

frequency

circuit

High Power

factor Correction

Converter

(AC → DC)

sensor

Input current

Filter

Noise

Inverter

(DC → AC)

Relay

circuit

of P.M.V.

Driver circuit

valve

4-way

P.M.V.

220–240 V ~ 50Hz

220 V ~ 60Hz

For INDOOR UNIT

Discharge

Outdoor air

temp. sensor

sensor

temp. sensor

Suction temp.

– 23 –

temp.sensor

Heat exchanger

9. OPERATION DESCRIPTION

9-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner, which uses DC motor for the indoor fan motor and the outdoor fan motor. And the capacityproportional control compressor which can change the motor speed in the range from 13 to 115 rps is mounted. The DC motor drive circuit is mounted to the indoor unit. The compressor and the inverter to control fan motor are mounted to the outdoor unit.

The entire air conditioner is mainly controlled by the indoor unit controller.

The indoor unit controller drives the indoor fan motor based upon command sent from the remote controller, and transfers the operation command to the outdoor unit controller.

The outdoor unit controller receives operation command from the indoor unit side, and controls the outdoor fan and the pulse motor valve. (P.M.V) Besides, detecting revolution position of the compressor motor, the outdoor unit controller controls speed of the compressor motor by controlling output voltage of the inverter and switching timing of the supply power (current transfer timing) so that motors drive according to the operation command. And then, the outdoor unit controller transfers reversely the operating status information of the outdoor unit to control the indoor unit controller.

As the compressor adopts four-pole brushless DC motor, the frequency of the supply power from inverter to compressor is two-times cycles of the actual number of revolution.

(1) Role of indoor unit controller

The indoor unit controller judges the operation commands from the remote controller and assumes the following functions.

• Judgment of suction air temperature of the indoor heat exchanger by using the indoor temp. sensor. (TA sensor)

• Judgment of the indoor heat exchanger temperature by using heat exchanger sensor (TC sensor) (Prevent-freezing control, etc.)

• Louver motor control

• Indoor fan motor operation control

• LED (Light Emitting Diode) display control

• Transferring of operation command signal (Serial signal) to the outdoor unit

• Reception of information of operation status (Serial signal including outside temp. data) to the outdoor unit and judgment/display of error

• Air purifier operation control

(2) Role of outdoor unit controller

Receiving the operation command signal (Serial signal) from the indoor unit controller, the outdoor unit performs its role.

• Compressor operation control

• Operation control of outdoor fan motor

• P.M.V. control

• 4-way valve control



Operations followed to judgment of serial signal



from indoor side.



• Detection of inver ter input current and current release operation

• Over-current detection and pre v ention oper ation to IGBT module (Compressor stop function)

• Compressor and outdoor fan stop function when serial signal is off (when the serial signal does not reach the board assembly of outdoor control by trouble of the signal system)

• Transferring of operation information (Serial signal) from outdoor unit controller to indoor unit controller

• Detection of outdoor temperature and operation revolution control

• Defrost control in heating operation (Temp. measurement by outdoor heat exchanger and control for four-way valve and outdoor fan)

(3) Contents of operation command signal (Serial

signal) from indoor unit controller to outdoor unit controller

The following three types of signals are sent from the indoor unit controller.

• Operation mode set on the remote control

• Compressor revolution command signal defined by indoor temperature and set temperature (Correction along with variation of room temperature and correction of indoor heat exchanger temperature are added.)

• Temperature of indoor heat exchanger

• For these signals ([Operation mode] and [Compressor revolution] indoor heat exchanger temperature), the outdoor unit controller monitors the input current to the inverter, and performs the followed operation within the range that current does not exceed the allowable value.

(4) Contents of operation command signal (Serial

signal) from outdoor unit controller to indoor unit controller

The following signals are sent from the outdoor unit controller.

• The current operation mode

• The current compressor revolution

• Outdoor temperature

• Existence of protective circuit operation For transferring of these signals, the indoor

unit controller monitors the contents of signals, and judges existence of trouble occurrence.

Contents of judgment are described below.

• Whether distinction of the current operation

status meets to the operation command signal

• Whether protective circuit operates

When no signal is received from the outdoor unit controller, it is assumed as a trouble.

– 24 –

9-2. Operation Description

No. Contents Page

9-2 1 Basic operation ................................................................................26

1) Operation control ............................................................................................. 26

2) Cooling/Heating operation ............................................................................... 26

3) AUTO operation ............................................................................................... 27

4) DRY operation ................................................................................................. 27

2 Indoor fan motor control...................................................................28

<In cooling operation> .......................................................................................... 28

<In heating operation>.......................................................................................... 29

3 Outdoor fan motor control................................................................30

4 Capacity control ...............................................................................31

5 Current release control ....................................................................31

6 Release protective control ...............................................................32

<In cooling/dry operation> .................................................................................... 32

<In heating operation>.......................................................................................... 32

7 Quick heating control .......................................................................33

8 Defrost control (Only in heating operation)......................................33

9 Louver control..................................................................................3 4

1) Louver position ................................................................................................ 34

2) Air direction adjustment ................................................................................... 34

3) Swing ............................................................................................................... 34

10 ECO operation .................................................................................35

11 Temporary operation........................................................................36

12 Air purifying control ..........................................................................3 7

Air purifying control [Detection of abnormality] ................................38

13 Discharge temperature control ........................................................38

14 Pulse Motor valve (PMV) control .....................................................39

15 Clean operation ...............................................................................40

16 Clean operation release..................................................................4 1

17 Select switch on remote controller ................................................... 42

9-3 Auto Restart Function ..............................................................................43

1 How to Set the Auto Restart Function..............................................43

2 How to Cancel the Auto Restart Function........................................44

3 Power Failure During Timer Operation.............................................44

9-4 FILTER Indicator ......................................................................................4 4

1 How to Turn Off FILTER Indicator ....................................................44

9-5 Remote Controller and Its Fuctions..........................................................4 5

1 Parts Name of Remote Controller....................................................45

2 Name and Functions of Indications on Remote Controller ..............46

9-6 Hi-POWER Mode .....................................................................................47

– 25 –

Item

Operation flow and applicable data, etc.

Description

1. Basic operation

1) Operation control Receiving the user’s operation condition setup, the opera-

tion statuses of indoor/outdoor units are controlled.

Remote controller

Selection

of operation

conditions

ON/OFF

Signal

receiving

Indoor unit

control

Operation

command

Serial signal

send/receive

Control contents of remote controller

• ON/OFF (Air conditioner/Air purifier)

• Operation select (COOL/HEAT/AUTO/DRY)

• Temperature setup

• Air direction

• Swing

• Air volume select (AUTO/LOW/LOW+/MED/MED+/HIGH)

• ECO

• ON timer setup

• OFF timer setup

• High power

Indoor unit

Indoor unit control

• Command signal generating function of indoor unit operation

• Calculation function (temperature calculation)

• Activation compensation function of indoor fan

• Cold draft preventive function

• Timer function

• Indoor heat exchanger release control

• Clean function

1) The operation conditions are selected by the remote controller as shown in the left.

2) A signal is sent by ON button of the remote controller.

3) The signal is received by a sensor of the indoor unit and processed by the indoor controllers as shown in the left.

4) The indoor controller controls the indoor fan motor and louver motor.

5) The indoor controller sends the operation command to the outdoor controller, and sends/receives the control status with a serial signal.

6) The outdoor controller controls the operation as shown in the left, and also controls the compressor, outdoor fan motor, 4-way valve and pulse motor valve.

• Indoor fan motor

• Louver motor

Outdoor unit

Serial signal

send/receive

Outdoor unit

control

Outdoor unit control

• Frequency control of inverter output

• Waveform composite function

• Calculation function (Temperature calculation)

• AD conversion function

• Quick heating function

• Delay function of compressor reactivation

• Current release function

• GTr over-current preventive function

• Defrost operation function

2) Cooling/Heating operation The operations are performed in the following parts by

controls according to cooling/heating conditions.

Operation ON

Indoor unit

control

Sending of

operation

command signal

Outdoor unit

control

Setup of remote controller

Indoor fan motor control Louver control

Compressor revolution control Outdoor fan motor control 4-way valve control

In cooling operation: ON

[ ]

In heating operation: OFF

Pulse motor valve control

Inverter

1) Receiving the operation ON signal of the remote controller, the cooling or heating operation signal starts being transferred form the indoor controller to the outdoor unit.

2) At the indoor unit side, the indoor fan is operated according to the contents of “2. Indoor fan motor control” and the louver according to the contents of “9. Louver control”, respectively.

3) The outdoor unit controls the outdoor fan motor, compressor, pulse motor valve and 4-way valve according to the operation signal sent from the indoor unit.

*1. The power coupler of

• Compressor

• Outdoor fan motor

• 4-way valve

• Pulse motor valve (PMV)

4-way valve is usually turned on, and it is turned off during defrost operation. (Only in heating)

– 26 –

Item

Operation flow and applicable data, etc.

Description

1. Basic operation

3) AUTO operation Selection of operation mode As shown in the following figure, the operation star ts by

selecting automatically the status of room temperature (Ta) when starting AUTO operation.

Cooling operation

Ts + 1

Monitoring (Fan)

Ts – 1

Heating operation

*1. When reselecting the operation mode, the fan speed

is controlled by the previous operation mode.

1) Detects the room temperature (Ta) when the operation started.

2) Selects an operation mode from Ta in the left figure.

3) Fan operation continues until an operation mode is selected.

4) When AUTO operation has started within 2 hours after heating operation stopped and if the room temperature is 20°C or more, the fan operation is performed with ”Super Ultra LOW” mode for 3 minutes. Then, select an operation mode.

5) If the status of compressor-OFF continues for 15 minutes the room temperature after selecting an operation mode (COOL/ HEAT), reselect an operation mode.

4) DRY operation DRY operation is performed according to the difference

between room temperature and the setup temperature as shown below.

In DRY operation, fan speed is controlled in order to prevent lowering of the room temperature and to avoid air flow from blowing directly to persons.

[˚C]

L– (W5)

1.0

0.5

(W5+W3) / 2

SL (W3)

Tsc

Fan speed

1) Detects the room temperature (Ta) when the DRY operation started.

2) Starts operation under conditions in the left figure according to the temperature difference between the room temperature and the setup temperature (Tsc). Setup temperature (Tsc) = Set temperature on remote controller (Ts) + (0.0 to 1.0)

3) When the room temperature is lower 1°C or less than the setup temperature, turn off the compressor.

– 27 –

Item

Operation flow and applicable data, etc.

Description

2. Indoor fan motor control

(This operation controls the fan speed at indoor unit side.) The indoor fan (cross flow fan) is operated by the phase-

control induction motor. The fan rotates in 5 stages in MANUAL mode, and in 5 stages in AUTO mode, respectively. (Table 1)

COOL ON

Fan speed setup

MANUAL

(Fig. 1)

AUTO

Indication Fan speed

L L+ M M+ H

(L + M) / 2

(M + H) / 2

(Fig. 2)

[˚C]

+2.5 +2.0

+1.5 +1.0

+0.5

Tsc

Air volume AUT O

M+(WB)

L(W6)

*3 : Fan speed =

(M + –L) x 3/4 + L

*4 : Fan speed =

(M + –L) x 2/4 + L

*5 : Fan speed =

(M + –L) x 1/4 + L

(Linear approximation from M+ and L)

* Symbols

UH : Ultra High H : High M+ : Medium+ M : Medium L+ : Low+ L: Low L- : Low– UL : Ultra Low SUL : Super Ultra Low

* The fan speed broadly varies due

to position of the louver, etc. The described value indicates one under condition of inclining downward blowing.

1) When setting the fan speed to L, L+, M, M+ or H on the remote controller, the operation is performed with the constant speed shown in Fig. 1.

2) When setting the fan speed to AUTO on the remote controller, revolution of the fan motor is controlled to the fan speed level shown in Fig. 2 and Table 1 according to the setup temperature, room temperature, and heat exchanger temperature.

(Table 1) Indoor fan air flow rate

– 28 –

Item

Operation flow and applicable data, etc.

Description

2. Indoor fan motor control

HEAT ON

Fan speed setup

AUTO

TC ≥ 42˚C

YES

*Fan speed =

(TC – (42 + a)) / 10 x (WD – W8) + W8

a : In up operation 1, in down operation 0

MANUAL

(Fig. 3)

Indication Fan speed

L L+ M M+ H

Min air flow rate control

52 51

42 41

Limited to Min WD tap

No limit

(L + M) / 2

(M + H) / 2

1) When setting the fan speed to L, L+, M, M+ or H on the remote controller, the operation is performed with the constant speed shown in Fig. 3 and Table 1.

2) When setting the fan speed to AUTO on the remote controller, revolution of the fan motor is controlled to the fan speed level shown in Fig. 5 according to the set temperature and room temperature.

3) Min air flow rate is controlled by temperature of the indoor heat exchanger (Tc) as shown in Fig. 4.

4) Cold draft prevention, the fa n speed is controlled by temperature of the indoor heat exchanger (Tc) as shown in Fig. 6.

(Fig. 4)

Basic fan control

[˚C]

TSC

–0.5

–1.0

–1.5

–2.0

–2.5 –5.0 –5.5

*1: Fan speed = (M + –L) x 1 ÷ 4 + L *2: Fan speed = (M + –L) x 2 ÷ 4 + L *3: Fan speed = (M + –L) x 3 ÷ 4 + L (Calculated with linear approximation from M+ and L)

(Fig. 5)

[In starting and in stability]

In starting

FAN AUTO

FAN Manual

• Until 12 minutes passed after operation start

• When 12 to 25 minutes passed after operation start and room temp. is 3°C or lower than set temp.

• Room temp. < Set temp. –4°C

Fan speed

AUTO

L (W8)

*1 *2

M+ (WD)

H (WE)

Cold draft preventive control

Tc 46 46 45 45 33

33 33 21 32 32 20

*A+4 *A+4 *A+4 *A-4 *A-4 *A-4

Fan speed in starting

* No limitation while fan speed MANUAL mode is in stability. * A: When Tsc ≥ 24, A is 24, and when Tsc < 24, A is Tsc Tsc: Set value

AUTO

Fan speed

AUTO

in stability

Fan speed

MANUAL

in starting

H (WE)

Line-approximate H and SUL with Tc.

SUL (W2)

Stop

(Fig. 6)

In stability

• When 12 to 25 minutes passed after operation start and room temp. is higher than (set temp. –3°C)

• When 25 minutes or more passed after operation start

• Room temp. ≥ Set temp . –3.5°C

– 29 –

Item

Operation flow and applicable data, etc.

Description

3. Outdoor fan motor control

The blowing air volume at the outdoor unit side is controlled.

Receiving the operation command from the controller of indoor unit, the controller of outdoor unit controls fan speed.

* For the fan motor, a DC motor with non-stage variable

speed system is used. However, it is limited to 8 stages for reasons of controlling.

Air conditioner ON

(Remote controller)

Indoor unit controller

1) Outdoor unit operation command (Outdoor fan control)

2) Fan speed ≥ 400

when the motor stopped.

Fan motor ON

3) Fan lock NO

4) Motor operates as shown in the table below.

YES

OFF status of

fan motor continues.

Air conditioner

OFF

Alarm

display

1) The operation command sent from the remote controller is processed by the indoor unit controller and transferred to the controller of the outdoor unit.

2) When strong wind blows at outdoor side, the operation of air conditioner continues with the fan motor stopped.

3) Whether the fan is locked or not is detected, and the operation of air conditioner stops and an alarm is displayed if the fan is locked.

4) According to each operation mode, by the conditions of outdoor temperature(To) and compressor revolution, the speed of the outdoor fan shown in the table is selected.

˚ ˚ ˚

˚ ˚

˚ ˚ ˚

Outdoor fan speed (rpm)

– 30 –

Item

Operation flow and applicable data, etc.

Description

4. Capacity control

The cooling or heating capacity depending on the load is adjusted.

According to difference between the setup value of temperature and the room temperature, the capacity is adjusted by the compressor revolution.

Remote controller Indoor unit

Set temp. (Ts) Room temp. (Ta)

Ts –Ta

Correction of Hz signal

Detection of electromotive force

of compressor motor winding

Detection of motor speed

and rotor position

Correction value of Hz

signal ≤ Operating Hz

Inverter output change

Commutation timing change

1) The difference between set temperature on remote controller (Ts) and room temperature (Ta) is calculated.

2) According to the temperature difference, the correction value of Hz signal which determines the compressor speed is set up.

3) The rotating position and speed of the motor are detected by the electromotive force occurred on the motor winding with operation of the compressor.

4) According to the difference resulted from comparison of the correction value of Hz signal with the present operation Hz, the inverter output and the commutation timing are varied.

5) Change the compressor motor speed by outputting power to the compressor.

* The contents of control

operation are same in cooling operation and heating operation

5. Current release control

Change of compressor speed

This function prevents troubles on the electronic par ts of the compressor driving inverter.

This function also controls drive circuit of the compressor speed so that electric power of the compressor drive circuit does not exceed the specified value.

Outdoor unit inverter main

circuit control current

Operating current ≤

Setup value

Low

Capacity control continues.

Outdoor temp.

45˚C 40˚C 44˚C 16˚C 39˚C 11˚C 15.5˚C

10.5˚C

High

Cooling current

release value

Outdoor temp. To

Setup of current release point

Reduce compressor speed

Current decrease

Heating current

release value

6.45A

6.75A

8.47A

7.72A

9.22A

10.80A

1) The input current of the outdoor unit is detected in the inverter section of the outdoor unit.

2) According to the detected outdoor temperature, the specified value of the current is selected.

3) Whether the current value exceeds the specified value or not is judged.

4) If the current value exceeds the specified value, this function reduces the compressor speed and controls speed up to the closest one commanded from the indoor unit within the range which does not exceed the specified value.

– 31 –

Item

Operation flow and applicable data, etc.

Description

6. Release protective control by temperature of indoor heat exchanger

(Prevent-freezing control for indoor heat exchanger) In cooling/dry operation, the sensor of indoor heat ex-

changer detects evaporation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value.

Usual cooling capacity control

When the value is in Q zone, the

compressor speed is kept.

Indoor heat exchanger temperature

7˚C

6˚C

5˚C

Reduction of compressor speed

1) When temperature of the indoor heat exchanger drops below 5°C, the compressor speed is reduced. (P zone)

2) When temperature of the indoor heat exchanger rises in the range from 6°C to under 7°C, the compressor speed is kept. (Q zone)

3) When temperature of the indoor heat exchanger rises to 7°C or higher, the capacity control operation returns to the usual control in cooling operation. (R zone)

(Prevent-over pressure control for refrigerating cycle) In heating operation, the sensor of indoor heat exchanger

detects condensation temperature and controls the compressor speed so that temperature of the heat exchanger does not exceed the specified value.

55˚C

50˚C

46˚C

Indoor heat exchanger temperature

Reduction of compressor speed

Usual heating capacity control

When the value is

in Q zone, the compressor speed is kept.

1) When temperature of the indoor heat exchanger rises in the range from 50°C to 55°C, the compressor speed is kept. (Q zone)

When temperature of the indoor heat exchanger drops in the range from 46°C to under 55°C, the compressor speed is kept. (Q zone)

2) When temperature of the indoor heat exchanger rises to 55°C or higher, the compressor speed is reduced. (P zone)

3) When temperature of the indoor heat exchanger does not rise to 50°C, or when it drops below to 46°C, the capacity control operation returns to the usual control in heating operation. (R zone)

– 32 –

Item

Operation flow and applicable data, etc.

Description

7. Quick heating control

8. Defrost control (Only in heating operation)

This function quickens the starting of heating operation when indoor/outdoor temperature is low. (Available only in heating operation)

When indoor temperature is low, this function stores the heat by heating winding depended on the outdoor temperature and then it enables the hot air blowing out quickly.

In case of operation stop

20˚C

The previous operation was

heating and 2 hours passed after the

operation had stopped.

YES

Winding is not heated

–1˚C –3˚C

–6˚C

temperature

Indoor temperature

–8˚C

Outdoor heat exchanger

Heating output for winding

20W or equivalent

OFF

(This function removes frost adhered to the outdoor heat exchanger.)

The temperature sensor of the outdoor heat exchanger (Te sensor) judges the frosting status of the outdoor heat exchanger and the defrost operation is performed with 4-way valve reverse defrost system.

Start of heating operation

0’ 10’ 15’ 27’40” 34’

–5˚C –7˚C

–20˚C

Outdoor heat exchanger temperature

The minimum value of Te sensor 10 to 15 minutes after

Operation time (Minute)

C zone

A zone

B zone

start of operation is stored in memory as Te0.

Table 1

A zone

B zone

C zone

When T e0 - TE ≥ 2.5 continued for 2 minutes in A zone, defrost operation starts.

When the operation continued for 2 minutes in B zone, defrost operation starts.

When T e0 - TE ≥ 3 continued for 2 minutes in C zone, defrost operation starts.

When the following conditions are satisfied, winding is heated by output varied by the outdoor heat exchanger temperature.

Condition 1 :

The previous operation was heating.

Condition 2 :

2 hours passed after operation stop.

Condition 3 :

The room temperature is 20°C or lower.

The indoor temperature sensor detects the room temperature. If the detected room temperature is 20°C or lower, the outdoor heat exchanger temperature sensor detects the outdoor heat exchanger temperature. As shown in the left figure, winding of the compressor is heated for each division of the temperature (

for each outdoor

temperature) and the heat is stored.

The necessity of defrost operation is detected by the outdoor heat exchanger temperature. The conditions to detect the necessity of defrost operation differ in A, B, or C zone each. (Table 1)

• Defrost operation in A to C zones

1) Stop operation of the compressor for 20 seconds.

2) Inver t (ON) 4-way valve 10 seconds after stop of the compressor.

3) The outdoor fan stops at the same time when the compressor stops.

4) When temperature of the indoor heat exchanger becomes 38°C or lower, stop the indoor fan.

• Returning conditions from defrost

operation to heating operation

1) Temperature of outdoor heat exchanger rises to +8°C or higher.

2) Temperature of outdoor heat exchanger is kept at +5°C or higher for 80 seconds.

3) Defrost operation continues for 15 minutes.

1) Stop operation of the compressor for approx. 50 seconds.

2) Inver t (OFF) 4-way valve approx. 40 seconds after stop of the compressor.

3) The outdoor fan starts rotating at the same time when the compressor starts.

– 33 –

Item

Operation flow and applicable data, etc.

Description

9. Louver control

1) Louver position

This function controls the air direction of the indoor unit.

• The position is automatically controlled according to the operation mode (COOL/HEAT).

• The set louver position is stored in memory by the microcomputer, and the louver returns to the stored position when the next operation is performed. (Cooling/heating memory position)

The angle of the louver is indicated as the horizontal angle is 0°. When the louver closes fully, it directs approx. 49° upward.

1) Louver position in cooling operation

Horizontal (0˚)

Cooling operation/ AUTO (COOL)/Dry

Initial setting of “Cooling storage position” Louver : Directs downward (9˚)

Hi Power

Room temp. (Ta) <

Set temp. (Tsc) + 3.5

Initial setting of “Cooling storage position” Louver : Directs downward (9˚)

Louver angle

Room temp. (Ta) ≥

Set temp. (Tsc) + 3.5

“Inclined blowing” Louver : Directs downward (14˚)

Cooling memory position

Inclined blowing

YES

Cooling/AUTO

(COOL)/DRY

operation

Powerful

operation

YES

Room temp. ≥ Set temp. +3.5

Cooling memory position

Room temp. ≥ Set temp. +3.5

YES

2) Air direction adjustment

2) Louver position in heating operation

Heating operation/

AUTO (HEAT)

Initial setting of “Heating storage position” Louver : Directs downward (76˚)

Horizontal

blowing

Inclined blowing

Room temp. (Ta) <

Set temp. (Tsc) – 3 or

25 minutes after start

of operation

“Heating storage position” Louver : Directs downward (76˚)

Air direction

Blowing

downward

ECO operation

Room temp. (Ta) ≥

Set temp. (Tsc) – 3

“Cooling storage position” Louver : Directs downward (9˚)

Inclined

blowing

Horizontal

blowing

Heating

operation

Heating memory position

YES

Heating memory position

Room temp. ≥ Set temp. –3.0

Room temp. ≥

Set temp. –3.0

Horizontal

ECO

operation

YES

position

• The louver position can be arbitrarily set up by pushing [FIX] button.

3) Swing

• Swing operation is perfor med in width 35° with the stop position as the center.

• If the stop position exceeds either upper or lower limit position, swing operation is performed in width 35° from the limit which the stop position exceeded.

– 34 –

• Swing When pushing [SWING] button during operation, the louver starts swinging.

Item

Operation flow and applicable data, etc.

Description

10. ECO operation

When pushing [ECO] button on the remote controller, a quiet and mild operation is performed by reducing the fan speed and the compressor speed.

This function operates the air conditioner with the difference between the set and the room temperature as shown in the following figure.

The time correction is performed for 8 minutes each. (However, the first correction is performed 150 seconds after start of the operation.)

Time correction

[˚C] +4.0 +3.5 +3.0 +2.5 +2.0 +1.5 +1.0 +0.5

TSC

–0.5 –1.0

–2.0

Zone

Frequency

DRY max

12 11 10

9 8 7 6 5 4 3 2 1

* 12 (DRY max - COOL min) /6 x 5 + COOL min * 11 (DRY max - COOL min) /6 x 4 + COOL min * 10 (DRY max - COOL min) /6 x 3 + COOL min

*12 *11 *10

*9 *8

COOL min

OFF

* 9 (DRY max - COOL min) /6 x 2 + COOL min * 8 (DRY max - COOL min) /6 x 1 + COOL min

Fan

L+ (W7)

L (W6)

L– (W5)

UL (W4)

+ 1

± 0

–1 zone: min 1

1) The room temperature (Tao) at the start time of DRY operation is detected.

2) According to difference between the room temperature and the set temperature (Tsc), the operation starts with the conditions shown in the left figure. Set temp. (Tsc) = Set temp. on remote controller (Ts) + (0.0 to 1.0)

3) If the room temperature is down by 2°C or more, turn off the compressor.

0 –0.5 –1.0 –1.5 –2.0 –2.5 –3.0 –4.0 –5.0 –6.0 –7.0 –8.0

(Room temp. – Set temp.)

–9.0

–10.0 –11.0

30 minutes

Time Compressor

speed

0Hz

A zone

16Hz

B zone

16 to 52Hz

C zone

52Hz

1) The indoor fan speed is controlled within W7 as maximum value.

2) Setting the compressor speed to Max. 52Hz, the temperature zone in which the operation can be performed with Max. 16Hz is gradually widened after 30 minutes passed when starting ECO operation.

3) The louver position is set horizontally (Standard cooling position) when the room temperature comes close to the set temperature or when 25 minutes passed after starting ECO operation.

– 35 –

DescriptionOperation flow and applicable data, etc.Item

11. Temporary operation

Pushing [RESET] button starts the temporary operation of [AUTO] operation. When keeping [RESET] button pushed for 10 seconds or more, the temporary [COOL] operation is performed.

FILTER indicator ON

Did you push

[RESET] button for

3 seconds or more?

YES

Did you push

[RESET] button for

10 seconds or more?

Switch to [AUTO RESTART] control.

YES

Push RESET button.

Temporary [AUTO] operation

Temporary [COOL] Operation

1) When pushing [RESET] button, the temporary [AUTO] operation star ts.

2) When keeping [RESET] button pushed for 3 seconds or more, Pi, Pi, Pi sound is heard and [AUTO RESTART] control is changed.

3) When keeping [RESET] button pushed for 10 seconds or more, “Pi” sound is heard and the temporary [COOL] operation starts.

4) If the FILTER indicator goes on, push [RESET] button to go off the FILTER indicator, and then push [RESET] button again.

5) To stop the temporary operation, push the button again.

– 36 –

DescriptionOperation flow and applicable data, etc.Item

12. Air purifying control

This function generates nagative ion while cleaning the air in the room.

If air purifier-ON signal is received while the air conditioner stops, the air purifier starts operation, and if it is received while the air conditioner operates, the air conditioner and the air purifier start operation. The air ion generator operates linked with the air purifying operation.

Sending air purifier-ON

1 2

Air conditioner stops Air conditioner operates

OPERATION indicator ON

Memory position

of louver/COOL

Fan ON

Air purifier ON

Air purifying operation

1,2

Start of air purifier-ON

Air conditioner +

air purifier operate

Present status

Stop

Air purifier only

Air conditioner

Joint use of AC

and air purifier

Operation button

PURE button

Air purifier

Stop (All)

AC + Air purifier

AC operation

Air conditioner

AC operation*

AC + Air purifier

All stop

* When the previous operation was the

operation of air conditioner + air purifier, an operation of air conditioner + air purifier starts by pushing AC button on the remote controller. (Operation of air conditioner + air purifier is stored in memory.)

Air purifying

operation

AC + Air purifying

operation

Louver*1

Cooling position

Follows to

AC operation

Fan speed *2

AUTO, L, L+, M,

M+, H

Follows to

AC operation

*1 Swing is available *2 Fan speed is Fan Auto mode varies in

order, (M + 1) → (L) → (L–) → (SL).

Sending air purifier-OFF

3 4

Air purifier operates Air conditioner +

Air purifier operate

OPERATION indicator OFF Filter-OFF

Fan stop

Air conditioner operates

Air purifier-OFF

Louver close

All stop

– 37 –

12. Air purifying control [Detection of abnormality]

Purifying operation

YES

FILTER indicator ON

Purifier power OFF

1 2 3

Total

operation time

1000H

Error input

YES

Purifier power ON

1 minute or less

YES

FILTER indicator ON

Purifier power OFF

FILTER incicator-OFF

continues.

Purifier power OFF

Error detection

Approx. 10 minutes

passed.

Purifier power ON

Error input

YES

1) Reset by RESET button.

2) Reset by RESET button or by the stop direction from the remote controller.

* When the breaker is turned [ON] (In restar t time

after power failure) or RESET button is pushed while the FILTER indicator is turned on, the air purifier is not turned on until the integrated operation time of the indoor fan exceeds 1 hour after operation start (It is nor the air purifier operation time). It is the safety measures considering an incomplete drain when electric dust collector has been cleaned with water.

DescriptionOperation flow and applicable data, etc.Item

1. Purpose

The air purifying control function is to alert the user to trouble in the ionizing or air purifying operation.

2. Description

Trouble is determined to have occurred (indicated by the FILTER indicator) in the following four cases.

1) When a count of 1000H has been reached on the timer

2) When the panel switch has been set to OFF by the opening of the air inlet grile, etc.

3) When an abnormal discharge caused by a symptom such as the build-up of dirt has been detected while the air purifier is ON

4) When the electric dust collector has not been installed correctly

* Trouble case (2) or (3) is deemed to

have occurred when the action concerned continues for more than one second.

3. Operation

The sequence that FILTER indicator is turned on are described in the left flowchart.

! When 1000H timer counts up, the

FILTER indicator keeps lighting even if the operation is stopped by the remote controller. The timer is stored in memory of the microcomputer, and the operation time is cleared by filter RESET button on the indoor unit or a power failure. (FILTER indicator goes off.)

" A trouble detected within 1 minute after

activation of the air is immediately judged as an error and the FILTER indicator goes on.

# In case that 1 minute passed after

activation of the purifier, the purifier is turned off while the PURE indicator keeps ON. After 10 minutes passed, restart the purifier and an error is judged again.

13. Discharge temperature control

Td value

117˚C 112˚C 108˚C 105˚C

98˚C

Control operation

Judges as an error and stops the compressor. Reduce the compressor speed. Reduce slowly compressor speed. Keeps the compressor speed. If the operation is performed with lower speed

than one commanded by the serial signal, speed is slowly raised up to the commanded speed.

Operates with speed commanded by the serial signal.

– 38 –

1. Purpose

This function detects error on the refrigerating cycle or error on the compressor, and performs protective control.

2. Operation

• Control of the compressor speed The speed control is performed as described in the left table based upon the discharge temperature.

Item

Operation flow and applicable data, etc.

Description

14. Pulse Motor valve (PMV) control

This function controls throttle amount of the refrigerant in the refrigerating cycle.

According to operating status of the air conditioner, this function also controls the open degree of valve with an expansion valve with pulse motor.

Starting up

Initialize

Move to

initial position

Compressor ON

SH control

PMV open degree control

release control

1) When starting the operation, move the valve once until it fits to the stopper. (Initialize)

* In this time, “Click” sound may be

heard.

2) Adjust the open degree of valve by super heat amount. (SH control)

3) If the discharge temperature was excessively up, adjust the open degree of valve so that it is in the range of set temperature. (Discharge temp. control)

4) When defrost operation is performed, the open degree of valve is adjusted according to each setup conditions during preparation for defrost and during defrost operation (4-way valve is inversed.).

5) To turn off the compressor while the air conditioner stops by control of the thermostat or by remote controller, adjust the open degree of valve to the setup value before stop of the compressor.

Stop by

remote controller

Power OFF

Room temp. sensor

(Ta sensor) control

* SH (Super Heat amount) =

Ts (Temperature of suction pipe of the compressor) – Tc or Te (Heat exchanger temperature at evaporation side)

* PMV: Pulse Motor Valve

Defrost

– 39 –

Item

Operation flow and applicable data, etc.

Description

15. Clean operation

Unit now performing cooling or dry operation

Push "stop" button

Only S.CLEAN indicator lights, and clean operation starts

Time set now elapses

Operation stops

• During clean operations: The louver opens slightly. The indoor fan operates continuously at a speed of 260 rpm.

Clean operation times

Operation mode Operation time

Cooling: Auto (cooling) Dry

Up to 10 minutes

From 10 minutes up to 1 hour

1 hour or longer

Clean operation time

No clean operation performed (0 minutes)

2 hours

4 hours

1. Purpose

The clean operation is to minimize the growth of mold, bacteria etc. by running the fan and drying so as to keep the inside of the air conditioner clean.

Clean operation

When the cooling or dry operation shuts down, the unit automatically starts the clean operation which is then performed for the specified period based on duration of the operation which was performed prior to the shutdown, after which the clean operation stops. (The clean operation is not performed after a heating operation.)

2. Operation

1) When the stop signal from the remote controller is received, the S.CLEAN indicator (green) on the main body lights, and the clean operation starts. (Neither the OPERATION indicator nor the TIMER indicator light.)

2) The period of the clean operation is determined by the duration of the operation performed prior to the reception of the stop code.

3) After the clean operation has been performed for the specified period, the unit stops operating.

Heating: Auto (heating)

Auto (fan only) Shutdown

No clean operation performed

• To stop an ongoing clean operation at any time Press the start/stop button on the remote controller

twice during the clean operation. (After pressing the button for the first time, press it for the second time without delay (within 10 minutes).)

– 40 –

Item

Operation flow and applicable data, etc.

Description

16. Clean operation release

Setting the clean operation release

Add J04 of the indoor P.C. board assembly. * This cancels the auto restart function.

Hold down the auto operation switch on the indoor unit for at least 3 seconds but not more than 10 seconds.

The indoor unit’s buzzer emits three beeps, and the OPERATION indicator flashes at 5 Hz intervals.

This completes the clean operation release setting.

Setting the clean operation

Cut J04 of the indoor P.C. board * This step may be skipped if the auto

restart function is not required.

* J04 will be near the

MUC so take steps to ensure that it will not be exposed to excessive levels of heat. Also take care to avoid solder bridging with the surrounding components.

Hold down the auto operation switch on the indoor unit for at least 3 seconds but not more than 10 seconds.

The indoor unit’s buzzer emits three beeps, and the OPERATION indicator flashes at 5 Hz intervals.

This completes the clean operation setting.

Outline diagram of P.C. board

J04

– 41 –

Item Description

Operation flow and applicable data, etc.

17. Select switch on remote controller

Push the operation button on the remote controller.

Both indoor units

start operation.

Unnecessary set

[Remote controller select]

HiPOWER

SWING

CLR

CLOCK

RESET

ECO

FAN

FIX

OFF

CHECK

Cutting direction

MEMO

1.3.5.9H

SLEEP

SET

Select “B” as the setting for one of the two indoor units

YES

and for the remote controller. (See below for details.)

Jumper wire

1. Purpose

This operation is to operate only one indoor unit using one remote controller.

2. Description

When operating one indoor unit in a situation where two indoor units have been installed in the same room or nearby rooms, this operation prevents the remote controller signal from being received simultaneously by both units, thus preventing both units from operating.

3. Operation

The indoor unit on which the remote controller selection has been set to B receives the signal of the remote controller also set to B. (At the factory the remote controller selection is set to A on all the indoor units. There is no A setting display.)

Setting the remote controller

Switching between A and B is enabled by cutting the jumper wire inside the battery box using pliers.

1) Slide open the remote controller cover and remove the batteries.

2) Cut the jumper wire inside the battery compartment using nippers.

• The jumper wire should not remain in contact

after being cut. Also, be careful not to let plastic scraps, jumper wire cuttings or other debris enter the inside of the remote controller.

3) Insert the batteries. “B” appears in the remote controller display.

* Even after the jumper wire has been cut,

switching between A and B is still possible by pressing the CHECK button and FIX button together. The A or B setting, which was switched by pressing the CHECK button and FIX button together, is restored to the setting established prior to the switching when the battery is replaced or the RESET button is pressed.

When switching between settings “A” and “B”, always switch the indoor unit board and the remote controller as a pair. (Otherwise, the indoor unit will not accept the remote controller’s signals.)

Setting the selector switch on the main unit

• Remove the front panel, and then set the selector

switch to “B”.

• After making the switch setting, remount the front

panel.

Position of remote controller selector switch

Selector switch

– 42 –

9-3. Auto Restart Function

This indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the event of a power supply being accidentally shut down. The operation will resume without warning three minutes after power is restored.

This function is not set to work when shipped from the factory. Therefore it is necessary to set it to work.

• When the unit is standby (Not operating)

9-3-1. How to Set the Auto Restart Function

To set the auto restart function, proceed as follows: The power supply to the unit must be on ; the

function will not set if the power is off. Push the [RESET] button located in the center of

the front panel continuously for three seconds. The unit receives the signal and beeps three times. The unit then restarts operating automatically in the

event of power supply being accidentally shut down.

Operation

Push [RESET] button for more than three seconds. (Less than 10 seconds)

RESET button

• When the unit is in operation

Operation

Push [RESET] button for more than three seconds. (Less than 10 seconds)

Motions

The unit is on standby.

↓

The unit starts to operate. The green indicator is on.

↓ After approx. three seconds,

The unit beeps three times The green indicator flashes and continues to operate. for 5 seconds

If the unit is not required to operate at this time, push [RESET] button once more or use the remote controller to turn it off.

Motions

The unit is in operation. The green indicator is on.

↓

The unit stops operating. The green indicator is turned off.

The unit beeps three times. The green indicator flashes

If the unit is required to operate at this time, push [RESET] button

RESET button

• When the unit is turned on by this function, the louver will not swing even though it was swinging automatically before shutting down.

• While the filter check indicator is on, the RESET button has the function of filter reset button.

once more or use the remote controller to turn it on.

↓ After approx. three seconds,

for 5 seconds

– 43 –

9-3-2. How to Cancel the Auto Restart Function

To cancel auto restart function, proceed as follows : Repeat the setting procedure : the unit receives the signal and beeps three times. The unit will be required to be turned on with the remote controller after the main power supply is turned off.

• When the system is on stand-by (not operating)

Operation

Push [RESET] button for more than three seconds. (Less than 10 seconds)

RESET button

• When the system is operating

Operation

Push [RESET] button for more than three seconds. (Less than 10 seconds)

Motions

The unit is on standby.

↓

The unit starts to operate. The green indicator is on.

↓ After approx. three seconds,

The unit beeps three times and continues to operate.

If the unit is not required to operate at this time, push [RESET] button once more or use the remote controller to turn it off.

Motions

The unit is in operation. The green indicator is on.

↓

The unit stops operating. The green indicator is turned off.

The unit beeps three times.

If the unit is required to operate at this time, push [RESET] button

RESET button

once more or use the remote controller to turn it on.

9-3-3. Power Failure During Timer Operation

When the unit is turned off because of power failure during timer operation, the timer operation is cancelled. In that case, set the timer operation again.

NOTE :

The Everyday Timer is reset while a command signal can be received from the remote controller even if it stopped due to a power failure.

↓ After approx. three seconds,

9-4. FILTER Indicator

When the elapsed time reaches 1000 hours after air purifier operation, the FILTER indicator lights.

After cleaning the filters, turn off the FILTER indicator.

9-4-1. How to Turn Off FILTER Indicator

Push [RESET] button on the indoor unit.

NOTE :

If [RESET] button is pushed while the FILTER indicator is not lit, the indoor unit will start the automatic operation.

When you want a temporary operation while the FILTER indicator lights, push [RESET] button to turn off the FILTER indicator. (See page 36)

– 44 –

9-5. Remote Controller and Its Fuctions

9-5-1. Parts Name of Remote Controller

a Infrared signal transmitter

Transmits signals t o the indoor unit.

b button

Press the button to start operation. (A receiving beep is heard.) Press the button again to stop operation. (A receiving beep is heard.) If no receiving sound i s heard from the indoor unit, press the button twice.

c Mode select button (MODE)

Press this button to select a mode. Each time you press the button, the modes cycle in order from A: Auto changeovercontrol, : COOL, : DRY, : HEAT back to A. (A receiving beep is heard.)

Temperature button ( )

TEMP

.. The temperature setting is increased to 30˚C.

... The temperature setting is reduced to 17˚C.

(A receiving beep is heard.)

e Fan speed button (FAN)

Press this button to s elect the fan s peed. When you select AUTO,thefanspeedisautomatically adjusted according to the room temperature. You can also manually select the desired fan speed from five available settings.

(LOW ,LOW+ , MED , MED+ , HIGH ) (A receiving beep is heard.)

f Auto louver button (SWING)

Press this button to swing the louver.(A receiving beep is heard.) Press the button again to stop the louver from swinging. (A receiving beep is heard.)

Set louver button (FIX)

Press this button to adjust the air flow direction. (A receiving beep is heard.)

h ON timer button (ON)

Use t his button to change the clock and ON timer times. To move up the time, press of the ON button.

To move down the time, press of the ON button.

OFF timer button (OFF)

Use t his button to change the OFF timer times.

and

n Automatic operationbutton (AUTO)

Press this button t o operate the air conditioner automatically. (A receiving beep is heard.)

o Economy button (ECO)

Press this button t o operate the air conditioner economically.

PRESET button

Pressthis buttonto operate the air conditioner according to the settings stored using the MEMO button.

q PURE button (PURE)

Press this button to start the electrical air purifying operation. Press the button again to stop operation.

Sleep timer button (SLEEP)

Press this button to start the sleep timer (OFF timer) operation. YoucanselecttheOFFtimertimefromamongfour settings (1, 3, 5 or 9 hours).

d c

l g

f k

PURE

MODE

HiPOWER

SWING

CLR

CLOCK RESET

FIX

CHECK

TEMP

ECO

FAN

OFF

AUTO

PRESET

MEMO

1.3.5.9H

SLEEP

SET

p o

m e r j i

To move up the time, press of the OFF button.

To move down the time, press of the OFF button.

OFF

j Reserve button (SET)

Press this button to store the time settings. (A receiving beep is heard.)

Cancel button (CLR)

Press this button to cancel the ON timer and OFF timer. (A receiving beep is heard.)

l High power button (Hi POWER)

Press this button to start high power operation.

Memory button (MEMO)

Press this button to ready forstoring the settings. Hold down the button for more than 3 seconds to store the setting indicated on t he remote control and until the

mark is displayed.

– 45 –

9-5-2. Name and Functions of Indications on Remote Controller

[Display]

All indicators, except for the clock time indicator,are displayed by pressing the button.

a Transmission mark

This transmission mark ( ) indicates when the remote controller transmits signals to the indoor unit.

Mode indicator

Indicates the current operation mode.

(AUTO: Automaticcontrol, A: Auto changeover control, : COOL, : DRY,

:HEAT)

c Temperature indicator

Indicates the te mperature s etting (17˚C to 30˚C).

d PURE indicator

Shows that the electrical air purifying operation is in progress.

FAN speed indicator

Indicates the selected fan speed. AUTO or one of five fan speed levels (LOW , LOW+ , MED , MED+ , HIGH ) can be shown.

Indicates AUTO when t he operating mode is either AUTO or : DRY.

TIMER and clock time indicator

The time setting fortimer operation or the clock time is indicated. The current time is always indicated except dur ing TIMER operation.

g Hi POWER indicator

Indicates when Hi POWER operation starts. Press the Hi POWER button to start and press it again to stop operation.

h (MEMORY) indicator

Flashes for 3 seconds when the MEMO button is pressed during operation. The mark is shown when holding down the button for more than 3 seconds while the mark is flashing. Press another button to turn off the mark.

ECO indicator

Indicates when the ECO is activated. Press the ECO button to start and press it again to stop operation.

j A, B change indicator remote control

• When the remote control switching function is set, “B” appears in the remote controller display. (When the remote control setting is“A”, there is no indication at this position.)

• Intheillustration,allindicatorsare shown forpurposes of explanation. During operation,onlytherelevant indicators are shown on the remote controller.

– 46 –

9-6. Hi-POWER Mode

([Hi-POWER] button on the remote controller is pushed.)

When [Hi-POWER] button is pushed while the indoor unit is in Auto, Cooling or Heating operation, Hi-POWER mark is indicated on the display of the remote controller and the unit operates as follows.

(1) Automatic operation

• The indoor unit operates in according to the current operation.

(2) Cooling operation

• The preset temperature drops 1°C. (The value of the preset temperature on the remote controller does not change.)

• If the difference between the preset temperature and the room temperature is big, the horizontal louver moves to the Hi-POWER position automatically. Then when the difference between them gets smaller, the horizontal louver returns automatically.

(3) Heating operation

• The preset temperature increases 2°C. (The value of the preset temperature on the remote controller does not change.)

(4) The Hi-POWER mode can not be set in Dry

operation

– 47 –

10. INSTALLATION PROCEDURE

10-1.Installation Diagram of Indoor and Outdoor Units

Zeolite-plus filter

140 mm or more

Hook

Plasma pure filter

47 mm or more

Mounting screw

Hook

Shield pipe

(for extension drain hose)

Installation

plate

74 mm or more

For the rear left and left piping

Wall

Insert the cushion between the indoor unit and wall, and tilt the indoor unit for better installation work.

Do not allow the drain hose to become slack.

Cut the piping hole slightly sloped

Make sure the drain hose is sloped downward.

Wireless remote control

Remote control holder (Mounting holes on both left and right sides)

Remote control holder mounting screw

Before installing the wireless remote control

• With the remote control cover removed, correctly load the supplied batteries while observing their polarity.

Wireless remote control

Cover

Batteries

Air filters

100 mm or

more from

When installing the outdoor unit, leave open in at least two of directions (A), (B), (C) and (D) shown in the right figure.

(C)

wall

200 mm or more

80 mm or more only when unobstructed to the front and both sides

In principle,

leave open

(B)

Ensure sufficient space to allow drainage

50 mm or more from wall

(D)

As shown in the figure, position power cord and connecting cable downward, and lead out along piping connection port.

(A)

250 mm or more from wall

power cord

Extension drain hose (Option: RB–821SW)

The auxiliary piping can be connected at the left, rear left, rear right, right, bottom right or bottom left as shown below.

Right

Rear right

Bottom right

Rear left

Bottom left

Left

Insulate the refrigerant pipes separately, not together.

6 mm thick heat resisting polyethylene foam

– 48 –

10-2.Optional Parts, Accesories and Tools

Optional Installation Parts

Part Code Parts name Q’ty

Refrigerant piping

RAS-B10EKVP-E, B13EKVP-E 6.35 mm 9.52 mm RAS-B16EKVP-E 6.35 mm 12.7 mm

Shield pipe (for extension drain hose) (polyethylene foam, 6 mm thick) 1

Indoor unit name

Liquid side

(Outer diameter)

Gas side

(Outer diameter)

1 ea.

Attachment bolt arrangement of outdoor unit

• Secure the outdoor unit with the attachment bolts and nuts if the unit is likely to be exposed to a strong wind.

Elongated drain hole

(j)

Suction side

• Use φ8 mm or φ10 mm anchor bolts and nuts.

If it is necessary to drain the defrost water, attach drain nipple to the

base plate of the outdoor unit before installing it.

Diffuser

Drain hole

(i)

Accessory and Installation Parts

Part No. Part name (Q’ty) Part No. Part name (Q’ty) Part No. Part name (Q’ty)

Installation plate x 1

Wireless remote control x 1

Remote control holder x 1

Zeolite-plus filter x 1

Mounting screw

φ4 x 25L x 6

Remote control holder

mounting screw

φ3.1 x 16L x 2

Battery x 2

Plasma pure filter x 1

Others Name This model is not equipped with an

Owner’s manual

Installation manual

extension drain hose.

Option:

For the extension drain hose, use the optionally available RB-821SW or a commercially available one.

– 49 –

Drain nipple* x 1

(RAS-10EAV P-E, 13EAVP-E,

16EAVP-E)

Water-proof rubber cap* x 2

(RAS-10EAV P-E, 13EAVP-E,

16EAVP-E)

Parts marked with asterisk (*) are packaged with the outdoor unit.

Installation/Service Tools

Changes in the product and components

In air conditioners using R410A, in order to prevent any other refrigerant from being accidentally charged, the service port diameter size of the outdoor unit control valve (3 way valve) has been changed. (1/2 UNF 20 threads per inch)

• In order to increase the pressure resisting strength of the refrigerant piping, flare processing diameter and opposing flare nuts sizes have been changed. (for copper pipes with nominal dimensions 1/2 and 5/8)

New tools for R410A

New tools for R410A Applicable to R22 model Changes

Gauge manifold As the working pressure is high, it is impossible to measure

the working pressure using conventional gauges. In order to prevent any other refrigerant from being charged, the port diameters have been changed.

Charge hose In order to increase pressure resisting strength, hose

materials and port sizes have been changed (to 1/2 UNF 20 threads per inch). When purchasing a charge hose, be sure to confirm the port size.

Electronic balance for refrigerant charging

As working pressure is high and gasification speed is fast, it is difficult to read the indicated value by means of charging cylinder, as air bubbles occur.

Torque wrench (nominal dia. 1/2, 5/8)

Flare tool (clutch type) By increasing the clamp bar’s receiving hole size, strength

Gauge for projection adjustment — Used when flare is made by using conventional flare tool. Vacuum pump adapter Connected to conventional vacuum pump . It is necessary to

Gas leakage detector Exclusive for HFC refrigerant.

• Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) and protector coating in the U.S’s ARI specified rose color (ARI color code: PMS 507).

• Also, the “charge port and packing for refrigerant cylinder” requires 1/2 UNF 20 threads per inch corresponding to the charge hose’s port size.

The size of opposing flare nuts have been increased. Incidentally, a common wrench is used for nominal diameters 1/4 and 3/8.

of spring in the tool has been improved.

use an adapter to prevent vacuum pump oil from flowing back into the charge hose. The charge hose connecting part has two ports — one for conventional refrigerant (7/16 UNF 20 threads per inch) and one for R410A. If the vacuum pump oil (mineral) mixes with R410A a sludge may occur and damage the equipment.

– 50 –

10-3. Installation of Indoor Unit

Installation Location

• A place which provides enough space around the indoor unit as shown in the diagram.

• A place where there are no obstacles near the air inlet and outlet.

• A place which allows easy installation of the piping to the outdoor unit.

• A place which allows the front panel to be opened.

• The indoor unit shall be installed so that the top of the indoor unit is positioned at least 2 m high.

•

Also, avoid putting anything on the top of the indoor unit.

CAUTION

• Direct sunlight on the indoor unit wireless receiver should be avoided.

• The microprocessor in the indoor unit should not be too close to r-f sources. (For details, see the o w ner’s manual.)

Remote control

• Should be placed where there are no obstacles, such as curtains, that may block the signal.

• Do not install the remote control in a place exposed to direct sunlight or close to a heating source, such as a stove.

• Keep the remote control at least 1 m away from the nearest TV set or stereo equipment. (This is necessary to prevent image disturbance or noise interference.)

• The location of the remote control should be determined as shown below.

(Side view)

Indoor unit

Reception range

(Top view)

Indoor unit

Remote control

*: Axial distance

Reception range

Remote control

Drilling a Hole and Mounting Installation Plate

Drilling a hole

When installing the refrigerant pipes from the rear.

The center of the pipe hole

Pipe hole

65 mm

42 mm

1. After determining the pipe hole position on the installation plate ( ) drill the pipe hole (φ65 mm) at a slight downward slant to

the out door side.

NOTE

• When drill ing into a wall that contains a metal lath, wire lath or metal plate, be sure to use a pipe hole brim ring sold separately.

– 51 –

Mounting the installation plate

Anchor bolt holes

25 mm

91 mm

Pipe hole

Indoor unit

g Mounting screw

a Installation plate

Pipe hole

When the installation plate is directly mounted on the wall

1. Securely fit the installation plate onto the wall by screws with the upper and lower catches, that hold the indoor unit, facing out.

2. To mount the installation plate on a concrete wall use anchor bolts. Drill the anchor bolt holes as illustrated in the above figure.

3. Install the installation plate horizontally and level.

CAUTION

When installing the installation plate with mounting screws, do not use anchor bolt holes. Otherwise the unit may fall down and result in personal injury and property damage.

Anchor bolt

5 mm dia. hole

Projection 15 mm or less

g Mounting screw

φ4 x 25L

Clip anchor (local parts)

CAUTION

Failure to securely install the unit may result in personal injury and/or property damage if the unit falls.

• In case of block, brick, concrete or similar type walls, drill 5 mm dia. holes in the wall.

• Insert clip anchors for the

mounting screws.

NOTE

• Install the installation plate using between 4 to 6 mounting screws, being sure to secure all four corners.

Electrical Work

1. The supply voltage must be the same as the rated voltage of the air conditioner.

2. Prepare a power source for the exclusive use of the air conditioner.

NOTE

• Wire type: More than H07RN-F or 245IEC66 (1.0 mm2 or more)

– 52 –

CAUTION

• This appliance can be connected to a main circuit breaker in either of the following two ways. (1) Connection to fixed wiring:

A switch or circuit breaker which disconnects all poles and has a contact separation of at least 3 mm must be incorporate in the fixed wiring. An approved circuit breaker or switch must used.

(2) Connection with power supply plug:

Attach power supply plug with power cord and plug it into wall outlet. An approved power supply cord and plug must be used.

NOTE

• Perform wiring work being sure the wire length is long enough.

Wiring Connection

How to connect the connecting cable

Wiring the connecting cable can be carried out without removing the front panel.

1. Remove the air inlet grille. Open the air inlet grille upward and pull it toward you.

2. Remove the terminal cover and cord clamp.

3. Insert the connecting cable (or as according to local regulations/codes) into the pipe hole on the wall.

4. Pull the connecting cable through the cable slot on the rear panel so that it protrudes about 15 cm out of the front.

5. Insert the connecting cable fully into the terminal block and secure it tightly with screws.

6. Tightening torque: 1.2 N·m (0.12 kgf·m)

7. Secure the connecting cable with the cord clamp.

8. Attach the terminal cover, rear plate bushing and air inlet grille on the indoor unit.

CAUTION

• Be sure to refer to the wiring system diagram labeled inside the front panel.

• Check local electrical regulations for any specific wiring instructions or limitations.

Terminal cover

Screw

Termi nal block

Earth wire

Connecting cable

Screw

Cord clamp

Terminal block

10 mm

70 mm

NOTE

Wire type: More than

H07RN-F or 245IEC66 (1.0 mm

or more)

Earth line

Connecting cable

about 15 cm

10 mm

50 mm

– 53 –

Piping and Drain Hose Installation

Piping and drain hose forming

• Since condensation results in machine trouble, make sure to insulate both the connecting pipes separately. (Use polyeth ylene foam as insulating material.)

Rear right

Rear left

Bottom left

Left

Bottom right

Right

Die-cutting front

panel slit

Changing

drain hose

Piping preparation

1. Die-cutting front panel slit

Cut out the slit on the left or right side of the front panel for the left or right connection and the slit on the bottom left or right side of the front panel for the bottom left or right connection with a pair of nippers.

2. Changing drain hose

For left connection, left-bottom connection and rear-left connection’s piping, it is necessary to relocate the drain hose and drain cap.

• How to remove the drain cap

Clamp drain cap with needle-nose pliers, and pull out.

• How to remove the drain hose

The drain hose is secured in place by a screw. Remove the screw securing the drain hose, then pull out the drain hose.

Screw

Drain hose

• How to attach the drain cap

1. Insert hexagonal wrench (4 mm).

2. Firmly insert drain cap.

No gap

Do not apply lubricating oil (refrigerant machine oil) when inserting the drain cap. If applied, deterioration and leakage of the drain plug may occur.

Insert a hexagon wrench (4 mm)

• How to attach the drain hose

Always use the original screw that secured the drain hose to the unit. Using a different screw may cause water to leak.

Insert the drain hose firmly until the connector contacts the insulation, then secure it in place using the original screw.

CAUTION

Securely insert the drain hose and drain cap; otherwise, water may leak.

– 54 –

In case of right or left piping

• After making slits on the front panel with a knife or similar tool, cut them out with a pair of nippers or an equivalent tool.

Slit

In case of bottom right or bottom left piping

• After making slits on the front panel with a knife or similar tool, cut them out with a pair of nippers or an equivalent tool.

Slit

Left-hand connection with piping

Bend the connecting pipes so that they are positioned within 43 mm above the wall surface. If the connecting pipes are positioned more than 43 mm above the wall surface, the indoor unit may be unstable. When bending the connecting pipe, make sure to use a spring bender to avoid crushing the pipe.

Refer to the table below for the bending radius of each connection pipe.

Outer diameter Bending radius

6.35 mm 30 mm

9.52 mm 40 mm

12.7 mm 50 mm

To connect the pipe after installation of the unit (figure)

(To the front of flare)

270 mm

170 mm

Gas side

Liquid side

R30 or less (φ6.35), R40 or less (φ9.52), R50 or less (φ12.7) Use polishing (polyethylene core or the like for bending pipe).

43 mm

Outward form of indoor unit

Use a screwdriver handle, etc.

NOTE

If the pipe is incorrectly bent, the indoor unit may be unstable on the wall. After passing the connecting pipe through the pipe hole, connect the connecting pipe to the auxiliary pipes and wrap the facing tape around them.

CAUTION

• Bind the auxiliary pipes (two) and connecting cable with facing tape tightly. In case of leftward piping and rear-leftward piping, bind the auxiliary pipes (two) only with facing tape.

Indoor unit

Auxiliary pipes

Installation plate

Connecting cable

• Carefully arrange the pipes so that none of the pipes stick out of the rear plate of the indoor unit.

• Carefully connect the auxiliary pipes and connecting pipes to each other and cut off the insulating tape wound on the connecting pipe to avoid double-taping at the joint, moreover, seal the joint with the vinyl tape, etc.

• Since condensation can result in machine performance trouble, be sure to insulate both connecting pipes. (Use polyethylene foam as insulating material.)

• When bending a pipe, be careful not to crush it.

– 55 –

Indoor Unit Installation

1. Pass the pipe through the hole in the wall, and hook the indoor unit on the installation plate at the upper hooks.

2. Swing the indoor unit to right and left to confirm that it is firmly hooked on the installation plate.

3. While pressing the indoor unit onto the wall, hook it at the lower part on the installation plate. Pull the indoor unit toward you to confirm that it is firmly hooked on the installation plate.

Hook here

a Installation plate

Hook

Press (unhook)

• For detaching the indoor unit from the installation plate pull the indoor unit toward you while pushing the bottom up at the specified

places.

Push

Drainage

1. Run the drain hose at a downward sloped angle.

NOTE

• Hole should be made at a slight downward slant on the outdoor side.

Do not route the drain hose upwards.

50 mm or more

Do not form the drain hose into a waved shape.

Do not put the drain hose end into water.

Do not put the drain hose end in a drainage ditch.

2. Put water in the drain pan and make sure that the water is being drained outside.

3. When connecting extension drain hose, insulate the connection par t of extension drain hose with shield pipe.

Shield pipe

Drain hose

Inside the room

Extension drain hose

CAUTION

Install the drain pipe for proper drainage. Improper drainage can result in water dripping inside the room.

This air conditioner has been designed to drain water collected from condensation which forms on the back of the indoor unit, to the drain pan. Therefore, do not locate the power cord and other parts at a height above the drain guide.

Space for pipes

Wall

Drain guide

– 56 –

10-4. Installation of Outdoor Unit

Installation Location

• A place which provides enough space around the outdoor unit as shown in the diagram.

• A place which can bear the weight of the outdoor unit and does not allow an increase in noise level and vibration.

• A place where the operation noise and discharged air do not disturb neighbors.

• A place which is not exposed to a strong wind.

• A place free of combustible gases.

• A place which does not block a passageway.

• When the outdoor unit is to be installed in an elevated position, be sure to secure its feet.

• This air conditioner accepts a connection piping length of up to 25 m.

• There is no need to add refrigerant as long as the length of the connection piping is 15 m or less.

• You will need to add 20 g of refr igerant per meter of added connection piping for installations requiring connection piping to be between 16 m to 25 m.

• An allowable height level is up to 10 m.

• A place where the drain water does not cause any problems.

Precautions for Adding Refrigerant

• Use a scale having a precision with at least 10 g per index line when adding the refrigerant. Do not use a bathroom scale or similar instrument.

• Use liquid refrigerant when refilling the refrigerant. Since the refrigerant is in liquid form, it can fill quickly. Therefore, perform the filling operation carefully and insert the refrigerant gradually.

CAUTION

1. Install the outdoor unit without anything blocking the discharging air.

2. When the outdoor unit is installed in a place always exposed to strong winds like on the coast or on a high story of a building, secure the normal fan operation using a duct or a wind shield.

3. Especially in windy areas, install the unit to prevent the admission of wind.

4. Installation in the following places may result in trouble. Do not install the unit in such places.

• A place full of machine oil.

• A saline-place such as the coast.

• A place full of sulfide gas.

• A place where high-frequency waves are likely to be generated, such

as from audio equipment, welders, and medical equipment.

Draining the water

• Holes are provided on the base plate of the outdoor unit to ensure that the defrost water produced during heating operations is drained off efficiently. If a centralized drain is required when installing the unit on a balcony or wall, follow the steps below to drain off the water.

1. Proceed with water-proofing by installing the water-proof rubber caps

2 elongated holes on the base plate of the outdoor unit. [How to install the water-proof rubber caps]

1) Place four fingers into each cap, and insert the caps into the water drain holes by pushing them into place from the underside of the base plate.

2) Press down on the outer circumferences of the caps to ensure that they have been inserted tightly. (Water leaks may result if the caps ha v e not been inserted properly, if their outer circumferences lift up or the caps catch on or wedge against something.)

2. Install the drain nipple

and a commercially available drain hose (with 16 mm

inside diameter), and drain off the water.

(For the position where the drain nipple

is installed, refer to the installation

diagram of the indoor and outdoor units.)

• Check that the outdoor unit is horizontal, and route the drain hose at a downward sloped angle while ensuring that it is connected tautly.

in the

Base plate

Strong wind

i Drain nipple

j Water-proof rubber

caps (supplied with the outdoor unit)

Base plate

Commercially available drain hose

– 57 –

Do not use ordinary garden hose, which can flatten and prevent water from draining.

Refrigerant Piping Connection

Flaring

1. Cut the pipe with a pipe cutter.

Obliquity

Roughness

Warp

2. Insert a flare nut into the pipe, and flare the pipe .

• Projection margin in flaring: A (Unit: mm)

Rigid (Clutch type)

Outer diameter of copper pipe R410A tool used Conventional tool used

6.35 0 to 0.5 1.0 to 1.5

9.52 0 to 0.5 1.0 to 1.5

12.7 0 to 0.5 1.0 to 1.5

Imperial (Wing nut type)

Outer diameter of copper pipe R410A

6.35 1.5 to 2.0

Die

Pipe

3. Flaring size : B (Unit : mm) Outer diameter of copper pipe

9.52 1.5 to 2.0

12.7 2.0 to 2.5

–0.4

R410A R22

6.35 9.1 9.0

9.52 13.2 13.0

12.7 16.6 16.2

• In case of flaring for R410A with the conventional flare tool, pull it out approx. 0.5 mm more than that of R22 to adjust to the specified flare size. The copper pipe gauge is useful for adjusting projection margin size.

Tighten the connection

Align the centers of the connecting pipes and tighten the flare nut as much as possible with your fingers. Then tighten the nut with a wrench and torque wrench as shown in the figure.

Half union

Externally threaded side

Use a wrench to secure.

Flare nut

Internally threaded side

Use a torque wrench to tighten.

CAUTION

• Do not apply excessive force. Otherwise, the nut may break.

(Unit: N·m)

Outer diameter of copper pipe Tightening torque

φ6.35 mm 14 to 18 (1.4 to 1.8 kgf·m) φ9.52 mm 33 to 42 (3.3 to 4.2 kgf·m) φ12.7 mm 50 to 62 (5.0 to 6.2 kgf·m)

• Tightening torque for connection of flare pipe The pressure of R410A is higher than R22. (Approx. 1.6 times.) Therefore securely tighten the flare pipes which connect the outdoor unit and the indoor unit with the specified tightening torque using a torque wrench. If any flare pipe is incorrectly connected, it may cause not only a gas leakage but also trouble in the refrigeration cycle.

Flare at indoor unit side

Flare at outdoor unit side

– 58 –

Evacuating

After the piping has been connected to the indoor unit, perform the air purge.

AIR PURGE

Evacuate the air in the connecting pipes and in the indoor unit using a vacuum pump. Do not use the refrigerant in the outdoor unit. For details, see the vacuum pump manual.

Use a vacuum pump

Be sure to use a vacuum pump with counter-flow prevention function so that oil inside the pump does not flow back into the air conditioner pipes when the pump stops. (If oil inside the vacuum pump enters into the air conditioner circuit which uses R410A, trouble with the refrigeration system may develop.)

1. Connect the charge hose from the manifold valve to the service port of the gas side packed valve.

2. Connect the charge hose to the port of the vacuum pump.

3. Open fully the low pressure side handle of the gauge manifold valve.

4. Operate the vacuum pump to begin evacuating. Perform evacuating for about 15 minutes if the piping length is 20 meters (15 minutes for 20 meters) (assuming a pump capacity of 27 liters per minute). Confirm that the compound pressure gauge reading is –101 kPa (–76 cmHg).

5. Close the low pressure valve handle of gauge manifold.

6. Open fully the valve stem of the packed valves (both sides of Gas and Liquid).

7. Remove the charging hose from the service port.

8. Securely tighten the caps on the packed valves.

Compound pressure gauge

–101 kPa (–76 cmHg)

Handle Lo

Charge hose

(For R410A only)

Pressure gauge

Manifold valv e

Handle Hi (Keep full closed)

Charge hose (For R410A only)

Connecting pipe

Packed valve at liquid side

Packed valve at gas side

Service port (Valve core (Setting pin))

CAUTION

• IMPORTANT POINTS FOR PIPING WORK

(1) Keep dust and moisture from entering the pipes. (2) Tighten connections carefully (between pipes and unit). (3) Evacuate the air in the connecting pipes using a VACUUM PUMP. (4) Check for gas leaks at all connections.

Vacuum pump adapter for counterflow prevent ion (For R410A only)

Vacuum pump

– 59 –

Packed valve handling precautions

• Open the valve stem all the way; but do not try to open it beyond the stopper.

• Securely tighten the valve stem cap with torque in the following table: Gas side

(φ12.7 mm) Gas side

(φ9.52 mm) Liquid side

(φ6.35 mm)

50 to 62 N·m (5.0 to 6.2 kgf·m)

33 to 42 N·m (3.3 to 4.2 kgf·m)

14 to 18 N·m (1.4 to 1.8 kgf·m)

Hexagon wrench is required.

4 mm

Service port 14 to 18 N·m

(1.4 to 1.8 kgf·m)

Wiring Connection

1. Remove the valve cover, the electric parts cover and the cord clamp from the outdoor unit.

2. Connect the connecting cable to the terminal as identified by the matching numbers on the terminal block of indoor and outdoor

unit.

3. Insert the power cord and the connecting cable fully into the terminal block and secure it tightly with screws.

4. Insulate the unused cords (conductors) from water entering in the outdoor unit. Locate them so that they do not touch any

electrical or metal parts.

5. Secure the power cord and the connecting cable with the cord clamp.

6. Attach the electric parts cover and the valve cover on the outdoor unit.

Stripping length of connecting cable

Termi nal block

123 LN

1012

Connecting cable

Model RAS-10EAVP-E RAS-13EAVP-E RAS-16EAVP-E Pow er source Maximum running current 12A

Installation fuse rating Power cord H07RN-F or 245IEC66 (1.5 mm

Connecting cable

Power cord

Earth line

H07RN-F or 245IEC66 (1.0 mm

Connecting cable

220–240V~, 50Hz

220V~, 60Hz

25A (D type )

Power cord

or more)

Earth line

CAUTION

• Incorrect wiring connection may cause electrical parts to burn out.

• Be sure to comply with local regulations/codes when running the wire from outdoor unit to indoor unit. (Size of wire and wiring method etc.)

• Every wire must be securely connected.

• This installation fuse (25A D type ) must be used for the power supply line.

• If incorrect or incomplete wiring is carried out, fire or smoke may result.

• Prepare the power supply for the exclusive use of the air conditioner.

• This product can be connected to the main breaker. Connection to fixed wiring: A switch which disconnects all poles and has a contact separation of at least 3 mm must be incorporated in the fixed wiring when connecting to a main breaker circuit.

– 60 –

10-5.Test Operation

Gas Leak Test

• Check the flare nut connections for gas leaks with a gas leak detector and/or soapy water.

Test Operation

To test the system, press and hold RESET button for 10 sec. (There will be one short beep.)

Check places for indoor unit

Electric parts cover

Check places for outdoor unit

Valve cover

RESET button

Auto Restart Setting

This product is designed so that, after a power failure, it can restart automatically in the same operating mode as before the power failure.

INFORMATIONINFORMATION

The product was shipped with Auto Restart function in the OFF position. Turn it ON as required.

How to set the Auto Restart

• Press and hold the RESET button for about 3 seconds. After 3 seconds, three short electric beeps will be heard to inform you that the Auto Restart has been selected.

• To cancel the Auto Restart, follow the steps described in the section Auto Restart Function on page 44.

Remote Control Selector Switch Setting

Remote control selector switch

• If two indoor units are installed in the same room or adjoining rooms, the second unit can inadvertently receive a remote control signal and start operation when operating the first unit. This can be prevented by setting one of the indoor units and the corresponding remote control to the B setting (the A setting is the default setting).

1. Setting the selector switch on the main unit

• Remove the front panel, and then set the selector switch to “B”.

• After making the switch setting, remount the front panel.

2. Setting the remote control

a Slide open the remote control cover and remove the batteries. b Cut the jumper wire inside the battery compartment using nippers.

• The jumper wire should not remain in contact after being cut. Also, be careful not to let plastic scraps, jumper wire cuttings or other debris enter the inside of the remote control.

c Insert the batteries. “B” appears in the remote control display.

3. Check that the indoor unit can be operated by the modified remote control.

Position of remote control se lector switch

Selector switch

HiPOWER

ECO

MEMO

1.3.5.9H

FAN

CLOCK RESET

SWING

CLR

FIX

CHECK

SLEEP

Jumper wire

SET

OFF

When switching between settings “A” and “B”, always switch the indoor unit board and the remote control as a pair. (Otherwise, the indoor unit will not accept the remote control’s signals.)

Cutting direction

– 61 –

11. HOW TO DIAGNOSE THE TROUBLE

The pulse motor circuits are mounted to both indoor

T able 11-1

and outdoor units. Theref ore , diagnose troubles according to the trouble diagnosis procedure as described below. (Refer to the check points in servicing written on the wiring diagrams attached to the indoor/outdoor units.)

No.

1 2 3 4 5 6

T roub leshooting Pr ocedure

First Confirmation Primary Judgment Judgment by Flashing LED of Indoor Unit Self-Diagnosis by Remote Controller Judgment of Trouble by Every Symptom How to Check Simply the Main Parts

Precautions when handling the new inverter (3DV Inverter)

! CAUTION: HIGH V OLTAGE

The high voltage circuit is incorporated. Be careful to do the check service, as the electric shock may be caused in case of touching parts on the

P.C. board by hand.

The new inverter (3DV inverter) will be incorporated starting with this unit.

(3D V : 3-shunt Discrete V ector control)

! !

! The control circuitry has an uninsulated construction.

! !

G-Tr

Compressor

IGBT x 6

Compressor

Page

64 65 65 66 69 78

Shared potential

MCU

Driver

Hall device

Amplifier

Separate potential

MCU

Photocoupler

Fan motor

FET(6 IN1

Photocoupler

JAVP-E series (insulated type) EAVP-E series (uninsulated type)

CAUTION!! A high voltage (equivalent to the supply voltage) is also energized

to ground through the sensors, PMV and other low-voltage circuits. The sensor leads and other wires are covered with insulated tubes for protection. Nevertheless, care must be taken to ensure that these wires are not pinched.

CAUTION!! T ake sufficient care to a v oid directl y touching any of the cir cuit

parts without first turning off the power.

CAUTION!! At times such as when the circuit board is to be replaced, place the

circuit board assembly in a vertical position.

Laying the board flat on an electrically conductive object (such as the top panel of the air conditioner's outdoor unit) while a charge is still retained by the electrolytic capacitors of the inverter's main circuit may cause short-circuiting between the electrolytic capacitors and secondary circuit components and result in damage to the components.

Driver

FET x 6

Amplifier

Fan motor

Sensor leads

Do NOT lay the circuit board assembly flat.

– 62 –

Precautions when inspecting the control section of the outdoor unit

NOTE :

A large-capacity electrolytic capacitor is used in the outdoor unit controller (inverter). Therefore, if the power supply is turned off, charge (charging voltage DC280 to 380V) remains and discharging takes a lot of time. After turning off the power source, if touching the charging section before discharging, an electrical shock may be caused. Discharge the electrolytic capacitor completely by using soldering iron, etc.

< Discharging method >

(1) Remove the inverter cover (plating) by opening f our mounting claws. (2) As shown below, connect the discharge resistance (approx. 100Ω40W) or plug of the soldering iron to voltage

between + – terminals of the C14 (“CAUTION HIGH VOLTAGE” is indicated.) electrolytic capacitor (500µF/ 400V) on P.C. board, and then perform discharging.

Inverter cover

Discharging position (Discharging period 10 seconds or more)

Plug of soldering iron

P. C. board (Soldered surface)

Fig. 11-1

– 63 –

11-1. First Confirmation

11-1-1. Confirmation of Power Supply

Confirm that the power breaker operates (ON) normally .

11-1-2. Confirmation of Power Voltage

Confirm that power voltage is AC 220–230–240 ± 10%. If power voltage is not in this range, the unit may not operate normally .

11-1-3. Operation Which is not a Trouble (Program Operation)

For controlling the air conditioner , the program oper ations are built in the microcomputer as described in the following table. If a claim is made for running operation, check whether or not it meets to the contents in the following tab le . When it does , we inform you that it is not trouble of equipment, but it is indispensable for controlling and maintaining of air conditioner.

T able 11-1-1

No.

When power breaker is turned “ON”, the OPERATION indicator (Green) of the indoor unit flashes.

Compressor may not operate even if the room temperature is within range of compressor-ON.

In Dry and ECO mode, FAN (air flo w) display does not change even though FAN (air flow select) button is operated.

Increasing of compressor motor speed stops approx. 30 seconds after operation started, and then compressor motor speed increases again approx. 30 seconds after.

Operation of air conditioner

Description

The OPERATION indicator of the indoor unit flashes when power source is turned on. If [START/STOP] button is operated once, flashing stops. (Flashes also in power failure)

The compressor does not operate while compressor restart delay timer (3-minutes timer) operates. The same phenomenon is found after power source has been turned on because 3-minutes timer operates.

The air flow indication is fixed to [AUTO].

For smooth operation of the compressor, the compressor motor speed is restricted to Max. 41 rps for 2 minutes, and Max.91 rps for 2 minutes to 3 minutes, respectively after the operation has started.

In AUT O mode , the operation mode is changed.

In HEAT mode, the compressor motor speed does not increase up to the maximum speed or decreases before the temperature arrives at the set temperature.

After selecting Cool or Heat mode, select an operation mode again if the compressor keeps stop status for 15 minutes.

The compressor motor speed may decrease by hightemp. release control (Release protective operation by temp.-up of the indoor heat exchanger) or current release control.

– 64 –

11-2. Primary Judgment

To diagnose the troubles, use the f ollowing methods. (1) Judgment by flashing LED of indoor unit (2) Self-diagnosis by service check remote controller (3) Judgment of trouble by every symptom

Firstly use the method (1) for diagnosis. Then, use the method (2) or (3) to diagnose the details of troubles.

11-3. Judgment by Flashing LED of Indoor Unit

While the indoor unit monitors the operation status of the air conditioner, if the protective circuit operates, the contents of self-diagnosis are displayed with block on the indoor unit indication section.

T able 11-3-1

Indoor indication

lamp flashes.

Which lamp

does flash?

Item

Check

code

Block display Description for self-diagnosis

OPERATION (Green) Flashing display (1 Hz)

OPERATION (Green) Flashing display (5 Hz)

OPERATION (Green) TIMER (Yellow) Flashing display (5 Hz)

OPERATION (Green) FILTER (Orange) Flashing display (5 Hz)

OPERATION (Green) TIMER (Yellow) FILTER (Orange) Flashing display (5 Hz)

Power failure (when power is ON)

Protective circuit operation for indoor P.C. board

Protective circuit operation for connecting cable and serial signal system

Protective circuit operation for outdoor P.C. board

Protective circuit operation for others (including compressor)

NOTES :

(1) The contents of items B and C and a part of item E are displayed when air conditioner operates. (2) When item B and C, and item B and a part of item E occur concurrently, priority is given to the block of item B. (3) The check codes can be confirmed on the remote controller for servicing.

– 65 –

11-4. Self-Diagnosis by Remote Controller (Check Code)

(1) If the indicators light as shown B to E in Table 11-3-1, excute the self-diagnosis by the remote controller. (2) When the remote controller is set to the service mode, the indoor controller diagnoses the operation condition

and indicate the information of the self-diagnosis on the display of the remote controller with the check codes. If a fault is detected, all indicators on the indoor unit will flash at 5Hz and it will beep for 10 seconds (Pi, Pi, Pi ... ). The TIMER indicator usually flashes (5Hz) during self-diagnosis.

11-4-1. How to Use Remote Controller in Service Mode

Push [CHECK] button with a tip of pencil to set the remote controller to the service mode.

• “ ” is indicated on the display of the remote controller.

Push [ON ] or [OFF ] button

If there is no fault with a code, the indoor unit will beep once (Pi) and the display of the remote controller will change as follows :

• • •

PURE

MODE

HiPOWER

SWING

CLR

CLOCK RESET

FIX

CHECK

AUTO

TEMP

PRESET

ECO

MEMO

1.3.5.9H

FAN

SLEEP

SET

OFF

Alphanumeric characters are used for the check codes.

is 5. is 6. is A. is B. is C. is D.

• The TIMER indicator of the indoor unit flashes continuously. (5 times per 1 sec.)

• Check the unit with all 52 check codes ( to ) as shown in Table-10-4-1.

• Push [ON ] or [OFF ] button to change the check code backward.

If there is a fault, the indoor unit will beep for 10 seconds (Pi, Pi, Pi...).

Note the check code on the display of the remote controller.

• 2-digits alphanumeric will be indicated on the display.

• All indicators on the indoor unit will flash. (5 times per 1 sec.)

Push [START/STOP] button to release the service mode.

• The display of the remote controller returns to as it was before service mode was engaged.

Time shotening method.

1. Push SET button while pushing CHECK button.

2. Push [START/STOP] button.

Fig. 11-4-1

– 66 –

11-4-2. Caution at Servicing

(1) After servicing, push the START/STOP b utton to return to the normal mode. (2) After servicing by the check code, turn off breaker of the power supply, and turn on breaker of the power

supply again so that memory in the microcomputer returns the initial status. However, the check codes are not deleted even if the power supply is turned off because they are stored in the fixed memory .

(3) After servicing, push [CLR] button under check mode status and then send the check code “7F” to the indoor

unit. The error code stored in memory is cleared.

T able 11-4-1

Block distinction

Check

code

Block

Indoor P.C. board etc.

Not displayed

Connecting cable and serial signal

Check

code

Operation of diagnosis function

Cause of operation

Short-circuit or disconnection of the room temperature sensor (TA sensor).

Being out of place, disconnection, shortcircuit, or migration of heat exchanger sensor (TC sensor)

Lock of indoor fan or trouble on the indoor fan circuit

Trouble on other indoor P.C. boards

Return serial signal is not sent to indoor side from operation started.

(1) Defective wiring of

connecting cable

(2) Operation of

compressor thermo. Gas shortage Gas leak

Air

conditioner

status

Operation continues.

All off

Operation continues.

Remarks

Displayed when error is detected.

Flashes when trouble is detected on Return serial signal, and normal status when signal is reset.

Judgment and action

1. Check the room temp. sensor.

2. When the room temp. sensor is normal, check P.C. board.

1. Check heat exchanger sensor.

2. When heat exchanger sensor is normal, check P.C. board.

1. Check the motor.

2. When the motor is normal, check P.C. board.

Replace P.C. board.

1. When the outdoor unit never operate:

(1) Check connecting cable,

and correct if defective wiring.

(2) Check 25A fuse of inverter

P.C. board.

(3) Check 3.15A of inverter P.C.

board.

2. To display [Other] block during operation, check compressor thermo. operation and supply gas (check gas leak also).

3. Unit operates normally during check. If Return serial signal does not stop between indoor terminal board 2 and 3, replace inverter P.C. board. If signal stops between indoor terminal board 2 and 3, replace indoor P.C. board.

– 67 –

Block distinction

Check

code

Block

Outdoor P.C. board

Check

code

Operation of diagnosis function

Cause of operation

Inverter over-current protective circuit operates. (Shor t time)

conditioner

All off

Air

status

Remarks

Displayed when error is detected.

Judgment and action

Even if trying operation again, all operations stop immediately. : Replace P.C. board.

Not displayed

Outdoor P.C. board

Others (including compressor)

Position-detect circuit error or short-circuit between windings of compressor

Current-detect circuit error

Being out of place, disconnection or shortcircuit of the outdoor heat exchanger sensor (TE) or suction temp. sensor (Ts)

Disconnection or shortcircuit of discharge temp. sensor

Outdoor fan drive system error

Outdoor heat exchanger temp. sensor error

Compressor drive output error, Compressor error (lock, missing, etc.), Break down

Return serial signal has been sent when operation started, but it is not sent from halfway.

(1) Compressor thermo.

operation Gas shortage Gas leak

(2) Instantaneous power

failure

Compressor does not rotate. (Current protective circuit does not operate when a specified time passed after compressor had been activated.)

Discharge temp. exceeded 117°C

Break down of compressor

Four-way valve inverse error (TC sensor value lowered during heating operation.)

All off

Operation continues

All off

Operation continues

All off

Operation continues

Displayed when error is detected.

——

Displayed when error is detected.

Flashes when trouble is detected on return serial signal, and normal status when signal is reset.

Displayed when error is detected.

——

1. Even if connecting lead wire of compressor is removed, position-detect circuit error occurred. : Replace P.C. board.

2. Measure resistance between wires of compressor, and perform short-circuit. : Replace compressor.

Even if trying operation again, all operations stop immediately. : Replace P.C. board.

1. Check sensors (TE, TS).

2. Check P.C. board.

1. Check discharge temp. sensor (TD).

2. Check P.C. board

Position-detect error, over-current protective operation of outdoor fan drive system, fan lock, etc. : Replace P.C. board or fan motor.

1. Check outdoor temp. sensor (TO).

2. Check P.C. board.

When 20 seconds passed after start-up, position-detect circuit error occurred. : Replace compressor.

Trouble on P.M.V.

1. Repeat Start and Stop with interval of approx. 10 to 40 minutes. (Code is not displayed during operation.) Supply gas. (Check also gas leak).

2. Unit operates normally during check. If return serial signal does not stop between indoor terminal block 2 and 3, replace inverter P.C. board. If signal stops between indoor terminal block 2 and 3, replace indoor P.C. board.

1. Trouble on compressor

2. Trouble on wiring of compressor (Missed phase)

1. Check dischage temp. sensor (TD).

2. Gas leakage

3. Trouble on P.M.V.

1. Check power voltage. (220–230–240 V +10%)

2. Overload operation of refrigeration cycle Check installation condition (Short-circuit of outdoor diffuser).

1. Check four-valve operation.

– 68 –

11-5. Judgment of Trouble by Every Symptom

11-5-1. Indoor Unit (Including Remote Controller)

(1 ) Po wer is not turned on (Does not operate entirely)

1. Is the supply voltage normal?

2. Is the normal voltage provided to the outdoor unit?

3. Is the crossover cable connected properly?

4. Is the fuse (F01) blown?

Operation

Check Item

Considerable principle cause

indicated on rear of

Is DC310–340V

supplied between

CN10 1 – 3 ?

Turn off power supply once, and 5 second later, turn it on again.

Is OPERATION indicator flashing?

Is fuse (F01)

of indoor control

board blown?

Is voltage

(DC12V or 5V)

indoor control board normal?

Parts of a power supply circuit

YES

Is it possible to turn on

power supply by pushing

[START/STOP] button

on remote controller?

YES YES

Unit operates normally.

YES YES

Parts (R04, R05, DB01, C01,

C03, IC01 and T01) are defective.

YES

defective.

Does transmission mark

NO NO

on remote controller flash

normally,and is its signal

transmitted properly?

Does fan

motor connector

between CN10 1 –

3 short-circuit?

Microcomputer

is defective.

Measures

Item by symptoms

Remote controller is defective.

Refer to (5) “Troubleshooting for remote controller”.

Replace main P.C. board

YES

Replace fan motor.

• Be sure to disconnect the motor connector CN10 after shut off the power supply, or it will be a cause of damage of the motor.

(2) Power is not turned on though Indoor P.C. board is replaced

Turn on power supply.

Does OPERATION indicator flash?

NO NO

YES YES

Is wired correctly to white and black

lead wires of terminal block?

Correct wiring.

To item of “Power supply is not turned on”.

– 69 –

(3) Only the indoor motor fan does not operate

1. Is it possible to detect the power supply voltage (AC220–240V) between # and $ on the terminal block?

2. Does the indoor fan motor operate in cooling operation?

(In heating operation, the indoor fan motor does not operate for approximately 10 minutes after it is turned on, to prevent a cold air from blowing in.)

Turn off power supply once, and turn it on again.

Does fan motor

continue to operate?

Start to operate indoor unit in cooling operation at airflow level “LOW”.

Does indoor

fan operate?

YES

Change airflow level to “HIGH”.

Is it possible to

change airflow level

to “HIGH”?

YES

Is it possible to detect

DC 1V or more between

5 + and 3 – of

motor connector (CN10).

YES

Is it possible to detect

DC 310–340V between

1 + and 3 – of motor

connector (CN10).

YES

(Motor connection condition)

Is it possible to detect DC 15V

between 4 + and 3 – of

motor connector (CN10).

YES

Start to operate the

indoor unit in except

heating operation.

At this time, is it possible to

detect DC 1V or more between

+ and 3 – of motor

connector (CN10)?

YES

Is it possible to

rotate cross-flow fan by

hand properly?

YES

Turn off indoor unit and remove connector from motor.

Then push START/STOP button on remote controller to stop flashing indicator on indoor unit.

Is it possible to detect

DC 15V between 4 +

and 3 – of motor

connector (CN10).

Turn off indoor unit and

remove connector from motor. Then start to operate indoor unit with remote controller.

Start to operate the

indoor unit in except

heating operation. At this time, is it possible to detect DC 1V or more

between

of motor connector (CN10)?

within 15 seconds after

(Check this condition

starting unit.)

YES

+ and 3 –

YES

Peplace indoor fan motor.

Peplace main P.C. board.

Peplace bearing.

Fan motor operates normally.

Turn off indoor unit

and rotate cross-flow

fan by hand when the

unit is on standby.

At this time, is it possible to

detect DC 1V or more

between

+ and 3 –

of motor connector

(CN10).

YES

– 70 –

(4 ) Indoor fan motor automatically starts to rotate by turning on power supply

<Cause>

The IC is built in the indoor fan motor. Therefore the P.C. board is also mounted to inside of the motor. If the P.C. board is soldered imperfectly or the IC is defective, the fan motor may automatically rotate by turning

on power supply.

1. Remove the front panel. (Remove 2 screws.)

2. Remove the cover of the fan motor lead wires.

3. Check DC voltage with CN10 connector while the fan motor is rotating.

NOTE :

• Do not disconnect the connector while the fan motor is rotating.

• Use a thin test rod.

Indoor fan starts rotating when power supply is turned on.

P.C. board

(Check output DC voltage of fan motor on P.C. board.)

Measure voltage between 3 (GND : BLACK)

and 5 (V line : YELLOW) of motor connector (CN10)

while indoor fan motor is rotating.

DC 1.0V or more

P.C. board is defective.

Replace P.C. board. Replace motor.

Under DC 1.0V

Motor is defective.

Yellow

Black

CN10

6 (Blue) 5 (Yellow) 4 (White) 3 (Black) 2 – 1 (Red)

– 71 –

(5 ) T r oub leshooting for remote contr oller

Check that A or B selected on the main unit is matched with A or B selected on the remote controller.

Is receiver

on indoor unit

exposed to

direct sunlight?

YES

Is there any

thyristor

fluorescent light

nearby?

YES

Push the START/STOP button.

Is transmission

mark indicated?

YES

Does indoor unit

operate when moving

remote controller

near receiver or

indoor unit?

YES

Batteries are

exhausted.

The unit does not beep at all. OPERATION indicator on indoor unit is not lit.

Push RESET button on remote controller with tip of pencil.

Avoid direct sunlight.

Keep indoor unit away from thyristor fluorescent light.

Does indoor unit

start to operate by

automatic restart

function?

YES

Does radio sound

is affected by remote

controller when a signal is

transmitted at distance of

5 cm from radio?

YES

P.C. board is defective.

Replace P.C. board.

Replace batteries.

Push the START/ STOP button

Is transmission

mark indicated?

YES

Does indoor unit

beep and operate?

YES

Normal

operation

Remote controller

is defective.

Replace remote controller.

NOTE : After replacing batteries,

push the RESET button with a tip of a pencil.

– 72 –

11-5-2. Wiring Failure (Interconnecting and Serial Signal Wire)

(1 ) Outdoor unit does not operate

1) Is the voltage between $ and % of the indoor terminal block varied? Confirm that transmission from indoor unit to outdoor unit is correctly performed based upon the following

diagram.

NOTE:

• Measurement should be performed 2 minutes and 30 seconds after starting of the operation.

• Be sure to prepare a diode for judgment.

Terminal block at indoor side

Red

White

Terminal block

S5277G

Tester

S5277G or equivalent (G or J type) (Diode with rated voltage of 400V or more is acceptable.)

Normal time : Voltage swings between DC15 and 60V. ....................Inv erter Assembly check (11-8-1)

Abnormal time : Voltage does not vary.

(2 ) Outdoor unit stops in a little while after operation started

<Check procedure> Select phenomena described below.

(1) The outdoor unit stops 10 to 20 minutes after operation started, and 10 minutes or more are required to

restart the unit.

Gas circulation amount is down.

Measure gas pressure.

Thermo. operation of compressor

Gas shortage Gas leak Pipe clogging

(2) If the unit stops once, it does not operate until the power will be turned on again.

To item of Outdoor unit does not operate.

(3) The outdoor unit stops 10 minutes to 1 hour after operation started, and an alarm is displayed.

(Discharge temp. error check code 03, 1E Sensor temp. error check code 02, 1C)

Gas leak P.M.V. is defective. Miswiring of connecting wires of indoor/outdoor units Clogging of pipe and coming-off of TC sensor

Refer to the chart in 11-6.

– 73 –

11- 6. Check Code 1C (Miswiring in indoor/outdoor units) and 1E

1C 1E

Gas leakage, disconnection of TS/TC sensors (Check code 02, 1C)

Valve drive check

Discharge temp. error, gas leakage (Check code 03, 1E)

Is coil of the pulse motor valve

(P.M.V.) correctly set?

YES

Is connecter of coil connected to inverter?

YES

from valve when the air conditioner starts the operation after turning off power

Is positioning sound of valve (sound hitting to stopper) heard

of the air conditioner once?

YES

Are temp. sensors of indoor/outdoor units correctly set to the holder? NOTE : The temperature sensors which are used to control pulse motor valve include indoor heat exchanger sensor (TC), outdoor heat exchanger temp. sensor (TE), outdoor suction temp. sensor (TS) and outdoor sensor (TO).

YES

Set it correctly.

Replace coil valve.

Set it correctly.

Gas amount check and valve clogging check

Remove TC sensor connector from the P.C. board in indoor unit. (Remove connector from the P.C. board.) Operate the air conditioner in COOL mode by TEMP button (“Pi” sound is heard if keeping pushed for 10 seconds.). The operation enters temporary operation mode which fixes opening degree of compressor speed. Check condensation at outlet of PMV, and then check operating pressure from the service port.

If there is condensation at outlet (1/4 inch=Ø6.35mm valve side),

Check the operating pressure from service port, and add gas if pressure is low.

Existence of condensation at outlet of P.M.V.

the valve is clogged.

YES

– 74 –

Replace valve.

Add gas.

11-7. Troubleshooting

11-7-1. How to Check Whether the Air Purifier is Good or Not

Turn off the power breaker once, and turn on again after 10 seconds.

Does the OPERATION indicator flash?

YES

Turn off the power breaker and remove CN34 (Micro switch connector). Short-circuit between and pin of CN34 at PC side, and turn on the power breaker after 10 seconds.

Is DC12V applied

between (Red/DC12V) and

(Brown/GND) of CN1 of the

Primary checkOperation check

micro-switch connector under

OFF status of the micro-switch

micro-switch connector under ON status of the micro-switch

1) Check operation while short-circuiting CN34 of the main P.C. board.

2) Perform air purifying operation by the remote controller.

3) Be sure not to touch the electric dust collector, ionizer , or ioniz ed wire unit with the human body.

1 1 2

high-voltage generator?

Is there conduction of

(Front panel opened)?

Is there conduction of

(Front panel closed)?

• In this time, check that the remote controller is in status which is shortened by time on the reactivation preventive timer and all display indicators go on for approx. 3 seconds when a signal is received. If time on the reactivation preventive timer is not shortened,

( )

the high-voltage is not applied to electrode of the air purifier for approx. 1 hour.

• While the air purifier operates, check that the fan speed [AUTO] is not displayed. (Because the power ON/OFF is controlled on the program)

1 2

YES

NO NO

YES

Is DC12V applied

between (+) and (–)

of CN33 of the main

P.C. board (MCC5020)?

YES

Micro-switch is stuck

Micro-switch malfunction

To item “Power supply is not turned on”

Replace the main P.C. board (MCC5020)

Replace micro-switch.

• Conduction check of micro-switch

Push the switch

→ ON

Release the switch

→ OFF

Tester

Does the indoor fan rotate?

YES

Does the PURE indicator (Blue) or

the FILTER indicator (Orange) go on?

YES

Does the PURE indicator

go off within 2 seconds after

it was ON, and does the FILTER

indicator (Orange) go on?

YES

Are the electric dust

collector and ionizer dried?

(Electrode check)

YES

Refer to items, cleaning and check for the electric dust collector/ionizer/ ionized wire units. When the ionized wire is disconnected or when dirt is

( )

not cleaned even cleaned, replace each unit.

Is DC-5V to DC-10V

applied between

(Brown/Negative voltage)

and (Brown/GND)

of CN33 of the main

P.C. board?

Dry the electric dust collector and ionizer.

Referring to the right figure, check the high-output voltage of the air filter unit. (NOTE) Use an exclusive high voltage tester; otherwise the tester may be broken.

Is output of the ionizer

approx. 4.0 kV to 4.8 kV?

Is output of the collector

approx. 3.0 kV to 3.8 kV?

Are the electric dust

YES

collector/ionizer/ionized

wire units dirty?

Is an abnormal sound

(cracking noise) heard

from the electrode?

YES

To item “Only indoor fan does not operate”

Replace the main P.C. board (MCC5020).

• How to check output of the air purifier

Be sure not to come to contact to the gray part or not to touch the ionized cables.

High-voltage tester

Replace the high-voltage generator.

No trouble

GND

Collector output

Ionizer output

– 75 –

11-7-2. How to Check Whether the Minus Ion Generator is Good or Not

Turn off the power breaker once, and turn on again after 10 seconds.

Does the OPERATION indicator flash?

YES

Turn off the power breaker and remove CN34 (Micro switch connector). Short-circuit between and pin of CN34 at PC side, and turn on the power breaker after 10 seconds.

Is DC12V applied

between (Red/DC12V) and (Brown/GND) of CN1 of the

Primary checkOperation check

micro-switch connector under

OFF status of the micro-switch

micro-switch connector under ON status of the micro-switch

1) Check operation while short-circuiting CN34 of the main P.C. board.

2) Perform air purifying operation by the remote controller.

3) Be sure not to touch the electrode with the human body.

high-voltage generator

in the air purifier?

Is there conduction of

(Front panel opened)?

Is there conduction of

(Front panel closed)?

( )

the high-voltage is not applied to electrode of the air purifier for approx. 1 hour.

• While the air purifier operates, check that the fan speed [AUTO] is not displayed. (Because the power ON/OFF is controlled on the program)

1 2

YES

Micro-switch is stuck

Micro-switch malfunction

To item “Power supply is not turned on”

Replace the power P.C. board

(MCC5020) or the housing assembly.

Replace micro-switch.

• Conduction check of micro-switch

Push the switch

→ ON

Release the switch

→ OFF

Tester

Does the indoor fan rotate?

YES

Does the PURE indicator (Blue) or

the FILTER indicator (Orange) go on?

YES

Does the PURE indicator

go off within 2 seconds after

it was ON, and does the FILTER

indicator (Orange) go on?

Referring to the right figure, check the high-voltage output of the air ionizer. In this time, peel the thermal insulator, and attach it to the original position after check operation.

NOTE : Use an exclusive high voltage tester; otherwise the tester may be broken.

Does the electrode

output approx. –6kV?

Replace the

high-voltage generator

YES

No trouble

To item “Only indoor fan does not operate”

Replace the main P.C. board (MCC5020).

To item “How to check whether

the air purifier is good or not”

• How to check output of minus ion <Caution on High Voltage!!>

high-voltage unit

Electrode

GND

– 76 –

High-voltage tester

11-8. How to Diagnose Tr ouble in Outdoor Unit

11-8-1. Summarized Inner Diagnosis of Inverter Assembly

T able 11-8-1

Diagnosis/Process flowchart Item

Preparation

Remove connector of compressor.

Check 25A fuse

(Part No.F01).

Check

terminal voltage

of electrolytic

capacitor.

Replace fuse.

Check

electrolytic

capacitor, diode

block (DB01),

etc.

Check

electrolytic

capacitor, diode

(DB01),

etc.

Check

Contents

Turn “OFF” the power supply breaker, and remove 3P connector which connects inverter and compressor.

• Check whether 25A fuse on the control board assembly is blown or not. (F01)

Summary

If fuse was blown, be sure to check the electrolytic capacitor and diode block. (DB01)

• Connect discharge resistance (approx. 100Ω40W) or soldering iron (plug) between +, – terminals of the electrolytic capacitor (760µF) of C14 (with printed CAUTION HIGH VOLTAGE) on P.C. board.

Discharging position (Discharging period 10 seconds or more)

Plug of soldering iron

Does outdoor

fan rotate?

YES

CN300 of outdoor fan

tester, check resistance

Replace outdoor fan motor.

Remove connector

motor, and using a

value between every

phases at motor side.

Operation

Measure-

ment

Check

Stop

Check

Measure-

ment

Turn on the power breaker, and operate the air conditioner in COOL mode by time shortening.

Measure terminal voltage of the electrolytic capacity.

760µF:400WV x 3

After operation, turn off the power breaker after 2 minutes 20 seconds passed, and discharge the electrolytic capacitor by soldering iron. Check voltage between motor phases.

• Is not winding between

", "-#

, or !-# opened

or short-circuited?

• Is not frame grounded with , or #?

!, "

OK if 760µF

→→

→

→→

DC280 to 380V Remove CN300 while

pushing the part indicated by an arrow because CN300 is a connector with lock.

→→

→ Resistance between

→→

phases should be approx. 55 to 77Ω

→→

→ Should be 10MΩ or

→→

more.

– 77 –

Diagnosis/Process flowchart Item

Contents

Summary

Check

Replace control board assembly.

Check

compressor

winding

resistance.

Replace

control board.

Replace

compressor.

Operation

11-9. How to Check Simply the Main

Parts

11-9-1. How to Check the P.C. Board

(Indoor Unit)

(1 ) Operating precautions

1) When removing the front panel or the P.C. board, be sure to shut off the power supply breaker.

2) When removing the P.C. board, hold the edge of the P.C. board and do not apply force to the parts.

3) When connecting or disconnecting the connectors on the P.C. board, hold the whole housing. Do not pull at the lead wire.

Check winding resistance between phases of compressor, and resistance between outdoor frames by using a tester.

• Is not grounded.

• Is not short-circuited between windings.

• Winding is not opened.

Remove connector CN300 of the outdoor fan motor, turn on the power supply breaker, and perform the operation. (Stops though activation is prompted.)

Check operation within 2 minutes 20 seconds after activation stopped.

(2 ) Inspection procedures

1) When a P.C. board is judged to be defective, check for disconnection, burning, or discoloration of the copper foil pattern on this P.C. board.

2) The P.C. board consists of the following 2 parts

a. Main P.C. boar d part :

DC power supply circuit (5V, 12V, 15V), Indoor fan motor control circuit, CPU and peripheral circuits, buzzer , and Driving circuit of louver.

b. Indication unit of infrared ray receiving

Infrared ray receiving circuit, LED :

To check defect of the P.C. board, follow the procedure described below .

→ OK if 10MΩ or more



→ OK if 0.51Ω → 0.57Ω



(Check by a digital tester.)



– 78 –

(3 ) Check procedures

T able 11-9-1

No.

Turn off the power supply breaker and remove the P.C. board assembly from electronic parts base. Remove the connecting cables from the terminal block.

Remove the connector of the motor and turn on the power supply breaker. If OPERATION indicator flashes (once per second), it is not necessary to check steps (1 to 3) in the right next column.

Push [START/STOP] button once to start the unit. (Do not set the mode to On-Timer operation.)

Shorten the restart delay timer and start unit.

Procedure

Check points

Check whether or not the fuse (F01) is blown.

Check power supply voltage :

1. Between No. 1 and No. 3 of CN23 (AC 220–240V)

2. Between + and – of C03 (DC 310–340V)

3. Between – of C10 and output side of IC08 (DC 15V)

4. Between 12V and GND

5. Between 5V and GND

Check power supply voltage :

1. Between CN21 and No. 1 of CN23 (DC 15–60V)

Check whether or not all indicators (OPERA TION, TIMER, FIL TER, Plasm

a) are lit for 3 seconds and

they return to normal 3 seconds later.

Causes

Impulse voltage was applied or the indoor fan motor short-circuited.

1. The terminal block or the crossover cable is connected wrongly.

2. The capacitor (C01), line filter (L01), resistor (R05), or the diode (DB01) is defective.

3. IC01, IC08 and T01 are defective.

4. IC01, IC08 and T01 are defective.

5. IC01, IC08, IC07 and T01 are defective.

IC03 and IC04 are defective.

The indicators are defective or the housing assembly (CN13) is defective.

Push [START/STOP] button once to start the unit,

• Shorten the restart delay timer.

• Set the operation mode to COOL.

• Set the fan speed level to AUTO.

• Set the preset temperature much lower than the room temperature. (The unit (compressor) operates continuously in the above condition.)

If the above condition (No. 5) still continues, start the unit in the following condition.

• Set the operation mode to HEAT.

• Set the preset temperature much higher than room temperature.

Connect the motor connector to the motor and turn on the power supply. Start the unit the following condition.

• Set the fan speed level to HIGH. (The unit (compressor) operates continuously in the above condition in No. 5.)

1. Check whether or not the compressor operates.

2. Check whether or not the OPERATION indicator flashes.

1. Check whether or not the compressor operates.

2. Check whether or not the OPERATION indicator flashes.

1. Check it is impossible to detect the voltage (DC 15V) between 3 and 4 of the motor terminals.

2. The motor does not operate or the fan motor does not rotate with high speed. (But it is possible to receive the signal from the remote controller.)

3. The motor rotates but vibrates strongly.

1. The temperature of the indoor heat exchanger is extremely low.

2. The connection of the heat exchanger sensor is loose. (The connector is disconnected.) (CN01)

3. The heat exchanger sensor and the P.C. board are defective. (Refer to Table 11-4-1.)

4. The main P.C. board is defective.

1. The temperature of the indoor heat exchanger is extremely high.

2. The connection of the heat exchanger sensor short-circuited. (CN01)

3. The heat exchanger sensor and the P.C. board are defective. (Refer to Table 11-4-1.)

4. The main P.C. board is defective

1. The indoor fan motor is defective. (Protected operation of P.C. board.)

2. The P.C. board is defective.

3. The connection of the motor connector is loose.

– 79 –

11-9-2. P.C. Board Layout

GND

+12V

[1] Sensor characteristic table

100

90 80 70 60 50 40 30

Resistance value (k )

20 10

0102030 4050

Temperature (˚C)

TA, TC, TO, TE, TS

+5V

TD : Discharge temp. sensor TA : Room temp. sensor TC : Heat exchanger temp. sensor TO : Outdoor temp. sensor TE : Outdoor heat exchanger temp. sensor TS : Suction temp. sensor

– 80 –

11-9-3. Indoor Unit (Other Parts)

No.

Room temp. (TA) sensor

Part name

Heat exchanger (TC) sensor

Remote controller

Louver motor

MP24GA

11-9-4. Outdoor Unit

No.

Compressor (Model : D A111A1F-20F1)

Part name

Checking procedure

Disconnect the connector and measure the resistance value with tester . (Normal temp.)

Temperature

Sensor

TA, TC (kΩ)

10°C 20°C 25°C 30°C 40°C

20.7 12.6 10.0 7.9 4.5

Refer to 11-5-1. (5). Measure the resistance value of each winding coil by using the tester.

(Under normal temp. 25°C)

White Yellow Yellow Yellow Yellow

Position

1 to 2 1 to 3 1 to 4 1 to 5

Resistance value

380 ± 40 Ω

Refer to 11-5-1. (3) and (4).Indoor fan motor4

Checking procedure

Measure the resistance value of each winding by using the tester.

Red

White Black

Position

Red - White

White - Black

Black - Red

Resistance value

0.88 to 0.98 Ω

Under 20°C

(Model : ICF-140-43-4)

4-way valve coil (Model : VHV)

Electronic control valve coil

(Model : CAM-MD12TF-1)

Outdoor temperature sensor

(TO), discharge temperature sensor (TD), suction temperature sensor (TS), outdoor heat exchanger temperature sensor (TE)

Measure the resistance value of winding by using the tester.Outdoor fan motor

Red

White Black

Position

Red - White

White - Black

Black- Red

Resistance value

17 to 25kΩ 17 to 25kΩ 17 to 25kΩ

Measure the resistance value of winding by using the tester.

Resistance value

1435±144 Ω

Under 20°C

Measure the resistance value of winding by using the tester.

COM

254

Position

Red - White

White - Orange

Brown- Y ellow

Brown- Blue

Resistance value

42 to 50kΩ 42 to 50kΩ 42 to 50kΩ 42 to 50kΩ

Under 20°C

Disconnect the connector, and measure resistance v alue with the tester. (Normal temperature)

Temperature

Sensor

TD (kΩ)

TO,TS,TE (kΩ)

10°C 20°C 25°C 30°C 40°C 50°C

100 64 50 41 27 18

20.7 12.6 10.0 7.9 4.5 –

– 81 –

11-9-5. Checking Method for Each Part

No.

Part name

Electrolytic capacitor (For boost, smoothing)

Diode block

Checking procedure

1. Turn OFF the power supply breaker .

2. Discharge all three capacitors completely.

3. Check that safety valve at the bottom of capacitor is not broken.

4. Check that vessel is not swollen or exploded.

5. Check that electrolytic liquid does not blow off.

6. Check that the normal charging characteristics are shown in continuity test by the tester.

C12 C13 C14

Case that product is good

Pointer s wings once , and returns slowly. When performing test once again under another polarity , the pointer should return.

Heat sink IGBT side

MCC-5009 Soldered surface

C12, C13, C14 → 760µF/400V

1. Turn OFF the power supply breaker .

2. Completely discharge the four electrolytic capacitors.

3. Remove the diode block from the PCB (which is soldered in place).

4. Use a multimeter with a pointer to test the continuity, and check that the diode block has the proper rectification characteristics.

–

+–

123

(DBO1)

Tester rod

+ – ~

–

Resistance value

in good product

10 to 20 Ω when the multimeter probe is

∞

reversed

– 82 –

11-10. How to Simply Judge Whether Outdoor Fan Motor is Good or Bad

1. Symptom

• Outdoor fan motor does not rotate.

• Outdoor f an motor stops within several tens seconds though it started rotating.

• Outdoor fan motor rotates or does not rotate according to the position where the fan stopped, etc. Remote controller check code “02 : Outdoor block, 1A : Outdoor fan drive system error”

2. Cause

The following causes are considered when the outdoor fan motor does not normally rotate.

1) Mechanical lock of the outdoor fan motor

2) Winding failure of the outdoor fan motor

3) Position-detect circuit failure inside of the outdoor fan motor

4) Motor drive circuit failure of the outdoor P.C. board

3. How to simply judge whether outdoor fan motor is good or bad

Turn OFF the breaker.

of the outdoor fan motor from the outdoor P.C. board.

Disconnect two connectors (CN300)

Does the fan rotate without trouble

when rotating it with hands?

YES

If the resistance value between 1 (Red lead) – 2 (White lead) 2 (White lead) – 3 (Black lead) 3 (Black lead) – 1 (Red lead)

of the connector

(CN300 : Motor winding)

is 17 to 25Ω, it is normal.

YES

Fan motor is normal.

(Outdoor P.C. board error)

CN300

Fan motor error

NOTE :

However, GND circuit error inside of the motor may be accepted in some cases when the abov e check is performed.

When the fan motor does not become normal ev en if P.C. board is replaced, replace the outdoor fan motor.

– 83 –

12. HOW TO REPLACE THE MAIN PARTS

WARNING

• Since high voltages pass through the electrical parts, turn off the power without fail before proceeding with the repairs. Electric shocks may occur if the power plug is not disconnected.

• After the repairs have been completed (after the front panel and cabinet have been installed), perform a test run, and check for smoking, unusual sounds and other abnormalities. If this check is omitted, a fire and/or electric shocks may occur. Before proceeding with the test run, install the front panel and cabinet.

• Ensure that the following steps are taken when doing repairs on the refrigerating cycle.

(1) Do not allow any naked flames in the surrounding area. If a gas stove or other appliance is being used,

extinguish the flames before proceeding. If the flames are not extinguished, they may ignite any oil mixed with the refrigerant gas.

(2) Do not use welding equipment in an airtight room. Carbon monoxide poisoning may result if the room is not

properly ventilated. (3 ) Do not bring welding equipment near flammable objects. Flames from the equipment may cause the flammable objects to catch fire.

• If keeping the power on is absolutely unav oidab le while doing a job such as inspecting the circuitry,

wear rubber gloves to avoid contact with the live parts.

Electric shocks may be received if the live parts are touched. High-voltage circuits are contained inside this unit. Proceed very carefully when conducting checks since directly touching the parts on the control circuit board may result in electric shocks.

12-1. Indoor Unit

No. RemarksProceduresPart name

Front panel

1) Stop operation of the air conditioner and turn off its main power supply.

2) Open the air inlet grille, push the arm toward the outside, and remove the grille.

3) Remove the left and right air filters, and remove the electric dust collector.

– 84 –

No. RemarksProceduresPart name

Front panel

4 )Push “ ” part under the front panel and

remove hooks of the front panel from the installation plate.

Installation plate

Front panel

Push

5) Remove the front panel fixing screws (2 pcs.).

6) Push the electric parts box with the right thumb while pulling the both sides of the front panel toward you.

Pull here

Push here

Press with your thumb

Push here

Pull here

1) Push three center positions and two lower

Electric dust

collector

center positions of the air outlet,

Holder

and then hang the hanging hooks (4 pcs.) at the top side of the front

Protrusion

panel to the rear plate.

2) Insert the electric dust collector and left and right air filters.

Push in the electric dust collector until the protrusions on both sides are completely inserted into the holders. If installation is incomplete, the FILTER indicator (orange) may light.

3) Tighten two screws.

• Incomplete hanging or incomplete pushing

may cause a dewdrops or generation of a fluttering sound.

Electric dust

collector

Holder

Protrusion

– 85 –

No. RemarksProceduresPart name

High voltage generator

1) Follow to the procedure in the item !.

2) Remove the drain guide.

3) To remo ve the air ionizer from the back body, pull it toward you while pressing down on its left and right claws. Disconnect the two leads (black) connected to the air ionizer from where they are fitted into the other components. (Caution: do not remo v e the Faston.)

4) Disconnect the connectors of the high-voltage generator, and disconnect the f our leads from where they are fitted into the other components.

5) Remove the fixing screw which secures the high voltage generator , and remov e the high v oltage generator from the evaporator .

Connector

Drain guide

Push the claw here

Air ionizer

Pull here

Push the claw here

Screw

– 86 –

No. RemarksProceduresPart name

High voltage generator

1) Insert the high voltage generator straight into the evaporator, and secure it using the fixing screw .

2) P ass the leads of the high v oltage gener ator through the area designated and insert them into its connectors.

3) Attach the air ionizer to the back body, and pass the two leads (black) through the area designated on the electric parts box assembly.

4) Attach the drain guide.

Check whether the leads have been completely inserted.

Claw

– 87 –

No. RemarksProceduresPart name

Electric parts

box assembly

1) Follow the procedure up to 4) in " above.

2) Remov e scre w of earth lead attached to the end plate of the evaporator.

3) Remov e the lead wire cov er, and remove connector (5P) for the fan motor and connector (5P) for the louver motor from the electric parts box assembly.

4) Pull out TC sensor from sensor holder of the evaporator.

TC sensor

Fan motor connector

Louver moter connector

Screw

Make absolutely sure that the leads form a loop

Lead wire cover

Fixing screw

5) Disengage the two claws at the top of the display unit. (They can be easily disengaged by pressing the drain pan above the claws and at the same time pulling the display unit toward you.)

6) Remove the fixing screw that secures the electric parts box assembly, and remove the assembly.

1) Hook the top part of the electric parts box assembly onto the claws on the back body, and secure it using the fixing screw. Now attach the display unit. Connect the connectors for the fan motor and louver motor .

2) Secure the grounding wire using the fixing screw. Insert the TC sensor into the sensor holder.

* Be absolutely sure to loop the grounding wire

and TC sensor leads once at the bottom.

Push the drain pan

Pull the display unit toward you

– 88 –

No. RemarksProceduresPart name

Horizontal louver

Evaporator (Heat exchanger)

1) Remove shaft of the horizontal louver from the back body. (First remo ve the left shaft, and then remove other shafts while sliding the horizontal louver leftward.)

1) Follow to the procedure in the item #.

2) Remove the pipe holder from the rear side of the main unit.

3) Remove two fixing screws at the left side of the end plate of the heat exchanger .

Screw

Slide the horizontal louver leftward

Pipe holder

Disengage the claw

Screw

4) Remove the heat exchanger fixing holder by removing the two fixing screws used to secure it.

5) Remove right side of the end plate from two fixing ribs while sliding slightly the heat exchanger rightward.

Screw

Heat exchanger fixing holder

Hanged part

– 89 –

No. RemarksProceduresPart name

Bearing 1) Follow to the procedure in the items !.

2) Remove the two fixing screws used to secure the left edge panel of the heat exchanger , and remove the two screws used to secure the bearing base.

Screw

Bearing base

Screw

3) Raise the left side of the heat exchanger slightly, and remove the bearing base.

• If the bearing is out from the housing, push it into

the specified position and then incorporate it in the main body.

• After assembling the bearing base, check that it

is fitted into the stepped part of the drain pipe.

Drain pipe

Bearing base

Remove in this direction

Bearing base

Raise the left side

Bearing

Drain pipe

– 90 –

No. RemarksProceduresPart name

Fan motor

1) Follow to the procedure in the item #.

2) Loosen the set screw of the cross flow fan.

3) Remove two fixing screws of the motor band (Right), and then remove the motor band (Right).

4) Pull the fan motor outward.

In assembling work, install the fan motor as follows.

• When assembling the fan motor, the f an motor

must be installed in such a way that the fan motor leads will be taken out is positioned at the bottom front.

• After assembling the two hooking claws of the

motor band (right) into the main body , position the fan motor, insert it, and then secure the motor band (right) using the two fixing screws.

Secure using the fixing screw

Screw

Set screw

(

Cross flow fan

Motor band (Right) Screw

Secure using the fixing screw

Fan motor leads

1) Follow to the procedure in the item &.

2) Remove the heat exchanger fixing holder by removing the two fixing screws used to secure it.

3) Loosen the set screw of the cross flow fan.

4) Lift the left side of the heat e xchanger, and pull out the cross flow fan.

Raise the left side

Pull out here

– 91 –

No. RemarksProceduresPart name

70.5mm

Joint

(

Cross flow fan

a) At assembling work of the bearing base, check

that the drain pipe is surely incorporated in the back body. (Otherwise, water leak is caused.)

Drain pipe

Bearing base

b) To incorporate the fan motor, remove the fan

motor rubber (at shaft core side), incorporate the motor into the position in the following figure, and then install the fan motor .

• Install the cross flow fan so that the right end

of the 1st joint from the right of the cross flow fan is set keeping 70.5mm from wall of rear plate of the main unit.

• Holding the set screw, install the cross flow

fan so that U-groove of the fan motor comes to the mounting hole of the set screw .

U groove

• Perform positioning of the fan motor as f o l-

lows:

• When assembling the fan motor, the f an motor

must be installed in such a way that the fan motor leads will be taken out is positioned at the bottom front.

• After assembling the two hooking claws of the

motor band (right) into the main body , position the fan motor, insert it, and then secure the motor band (right) using the two fixing screws.

– 92 –

12-2. Microcomputer

No.

Part name

Common procedure

<P.C. board layout>

Procedure

1) Turn the power supply off to stop the operation of air-conditioner.

2) Remove the front panel.

• Remove the 2 fixing screws.

3) Remov e the electrical part base.

R05 L01 C01 CN23 FUSE R04 R01 CN10

Remarks

Replace terminal block, microcomputer assembly and the P.C. board assembly.

DB01

C03

T01

IC03C20IC01

J04

– 93 –

12-3. Outdoor Unit

No. RemarksProceduresPart name

Common procedure

1. Detachment NOTE :

Wear gloves for this job. Otherwise, you may injure your hands on the parts, etc.

1) Stop operation of the air conditioner , and turn off

the main switch of the breaker for air conditioner.

2) Remov e the valve cover . (ST1TØ4 x 8

l 1 pc.)

• After removing screw, remove the valve cover pulling it downward.

3) Remove wiring cover (ST1TØ4 x 8

l 2 pcs.), and

then remove connecting cable.

4) Remove the upper cabinet. (ST1TØ4 x 8

l 5 pcs.)

• After removing screws, remove the upper

cabinet pulling it upward.

2. Attachment

1) Attach the water-proof cover.

NOTE : The water-proof cover must be attached without fail in order to prevent rain water , etc. from entering inside the indoor unit.

Upper cabinet

Valve cover

Insert the bent part into the rear panel of the inverter

Water proof cover

Bring into contact against these parts

2) Attach the upper cabinet. (ST1TØ4 x 8

l 5 pcs.)

3) P erform cabling of connecting cable, and attach the wiring cover.

• Place the wiring cover over the opening used

to work on the connecting wires of the side cabinet, and secure it using the two fixing screws (ST1TØ4 x 8

l 2 pcs.). At this point,

the top cushion of the wiring cover must be on the inside of the opening.

4) Attach the valve cover. (ST1TØ4 x 8

l 1 pc.)

• Insert the upper part into the square hole of

the side cabinet, set hook claws of the valve cover to square holes (at three positions) of the main unit, and attach it pushing upward.

Align the stitch line with the top edge of the front cabinet

How to mount the water-proof cover

Bend downward, and align with the inside surface of the front cabinet

– 94 –

No. RemarksProceduresPart name

Front cabinet

1. Detachment

1) Perform step 1 in 1.

2) Remove the fixing screws (ST1TØ4 x 8

l l

l 2 pcs.)

l l

used to secure the front cabinet and inverter cover, the screws (ST1TØ4 x 8

l 3 pcs.) used to

secure the front cabinet at the bottom, and the fixing screws (ST1TØ4 x 8

l 2 pcs.) used to

secure the motor base.

• The front cabinet is fitted into the side cabinet (left) at the front left side so pull up the top of the front cabinet to remove it.

2. Attachment

1) Insert the claw on the front left side into the side cabinet (left).

2) Hook the bottom part of the front right side onto the concave section of the bottom plate. Insert the claw of the side cabinet (right) into the square hole in the front cabinet.

3) Return the screws that were removed above to their original positions, and attach them.

Front cabinet

Claw

Square hole

Concave section

– 95 –

No.!Part name

Procedure

Remarks

Inverter assembly

1) Perform work of item 1 in ".

2) Remove screw (ST1TØ4 x 8

l 2 pcs.) of the upper

part of the front cabinet.

• If removing the inverter cover in this condition, P.C. board can be checked.

• If there is no space above the unit, perform work of 1 in #.

Be careful to check the inverter because high-voltage circuit is incorporated in it.

3) Perf orm discharging by connecting , polarity by discharging resistance (approx. 100Ω40W) or

plug of soldering iron to , terminals a of the C14 (printed “CAUTION HIGH VOLTA GE” is attached.) electrolytic capacitor (760µF) on P.C. board.

Be careful to discharge the capacitor because the electrolytic capacitor cannot naturally discharge and voltage remains according to trouble type in some cases.

Inverter cover

Discharging position (Discharging period 10 seconds or more)

A screw (STIT-4X8MSZN)

P. C. board (Soldered surface)

Plug of soldering iron

Terminal block

NOTE : This capacitor is one with mass capacity . Therefore, it is dangerous that a large spark

generates if short-circuiting between , polarity with screwdriver , etc. for disc harging.

4) Remove screw (ST1TØ4 x 8

l 2 pcs.) fixing the

main body and the inverter box.

5) Remove the front cabinet by performing step 1 in

#, and remove the fixing screws (ST1TØ4 x 8

for securing the main body and inverter box.

6) Remove various lead wires from the holder at upper part of the inverter box.

7) Pull the inverter box upw ard.

8) Disconnect connectors of various lead wires.

Requirement : As each connector has a lock mechanism, avoid to remove the connector by holding the lead wire, but b y holding the connector.

Put the compressor leads through the hole

l l

l )

l l

The connector is one with lock, so remove it while pushing the part indicated by an arrow .

Put each leads through the hole

– 96 –

Be sure to remove the connector by holding the connector, not b y pulling the lead wire.

No. RemarksProceduresPart name

P.C. board base

P.C. board

CN700 CN602 CN300

CN701

CN603

CN601 CN600

Control board

assembly

1) Disconnect the leads and connectors connected to the other parts from the control board assembly.

1) Leads

• 3 leads (black, white, orange) connected to SL connectors.

• Lead connected to compressor : Disconnect the connector (3P).

• Lead connected to reactor : Disconnect the two connectors (2P).

2) Connectors (x8) CN300 : Outdoor fan motor (3P: white)*

(See Note) CN701 : 4-way valve (2P: yellow)* CN600 : TE sensor (2P: white)* CN700 : PMW (6P: white) CN603 : TS sensor (3P: white)* CN601 :TD sensor (3P: white)* CN602 : T O sensor (2P: white)

Note :

These connectors have a disconnect prevention mechanism: as such, the lock on their housing must be released before they are disconnected.

CN300, CN701, CN600 and CN603 are connectors with locking mechanisms: as such, to disconnect them, they must be pressed in the direction of the arrow while pulling them out.

2) Remove the control board assembly from the P.C. board base. (Remove the heat sink and control board assembly while keeping them screwed together .)

Note :

Disengage the four claws of the P.C. board base, hold the heat sink, and lift to remove it.

3) Remove the two fixing screws used to secure the heat sink and control board assembly.

4) Mount the new control board assembly.

Note :

When mounting the new control board assembly, ensure that the P.C. board is inserted properly into the P.C. board support groove.

– 97 –

No. RemarksProceduresPart name

Side cabinet

1. Side cabinet (right)

1) Perform step 1 in ! and all the steps in ".

2) Remove the fixing screw (ST1TØ4 x 8

l 5 pcs.)

used for securing the side cabinet to the bottom plate and valve fixing panel.

2. Side cabinet (left)

1) Perform step 1 in !.

2) Remove the fixing screw (ST1TØ4 x 8

l 1 pcs.)

used to secure the side cabinet (left) onto the heat exchanger .

3) Remove the fixing screw (ST1TØ4 x 8

l 2 pc.)

used for securing the side cabinet to the bottom plate and heat exchanger .

Detail A Detail B Detail C

Hook the claw onto the bottom plate here.

The back body section is hooked onto the bottom plate here.

– 98 –

No. RemarksProceduresPart name

(

Fan motor

1) Perf orm work of item 1 of ! and ".

2) Remove the flange nut fixing the fan motor and

the propeller.

• Flange nut is loosened by turning clockwise. (To tighten the flange nut, turn counterclockwise.)

3) Remove the propeller fan.

4) Disconnect the connector for fan motor from the inverter.

5) Remove the fixing screws (2 pc.) holding by hands so that the fan motor does not fall.

* Precautions when assembling the fan motor

Tighten the flange nut using a tightening torque of 4.9 N•m.

# Compressor 1) Perf orm work of item 1 of

2) Extract refrigerant gas.

3) Remove the partition board. (ST1TØ4 x 8

4) Remove the sound-insulation material.

5) Remove terminal cover of the compressor, and disconnect lead wire of the compressor from the terminal.

6) Remove pipe connected to the compressor with a burner.

• Take care to keep the 4-way v alve away from naked flames. (Otherwise, it may malfunction.)

7) Remove the fixing screw of the bottom plate and heat exchanger . (ST1TØ4 x 8

8) Remove the fixing screw of the bottom plate and valve fixing plate. (ST1TØ4 x 8

9) Pull upward the refrigeration cycle.

10) Remove BOLT (3 pcs.) fixing the compressor

to the bottom plate.

* Precautions when assembling the compressor.

Tighten the compressor bolts using a tightening torque of 4.9 N•m.

l 3 pcs.)

l 1 pc.)

and ", $, %, &.

l 1 pc.)

Propeller fan

Fan motor

Partition board

Compressor

Flange nut

Valve fixing plate

' Reactor 1) Perform work of item 1 of ", and

2) Remove screws fixing the reactor. (ST1TØ4 x 8

l 4 pcs.)

– 99 –

Reactor

No. RemarksProceduresPart name

)

Electronic expansion valve coil

Fan guard

1. Detachment

1) Perform step 1 in ", all the steps in # and 1 in

2) Remove the coil by pulling it up from the elec-

tronic control valve body.

2. Attachment

1) When assembling the coil into the valve body,

ensure that the coil anti-turn lock is installed properly in the pipe.

When handling the parts, do not pull the leads. When removing the coil from the valve body, use your hand to secure the body in order to prevent the pipe from being bent out of shape.

1. Detachment

1) P erform work of item 1 of ".

2) Remove the front cabinet, and put it down so that fan guard side directs downward.

Coil anti-turn lock

Coil anti-turn lock position

Coil inserting position

Minus screwdriver

Hooking claw

Perform work on a corrugated cardboard, cloth, etc. to prevent flaw to the product.

3) Remove the hooking claws by pushing minus screwdriver according to the arrow mark in the right figure, and remove the fan guard.

2. Attachment

1) Insert claws of the fan guard in the holes of the front cabinet. Push the hooking claws (9 positions) by hands and fix the claws.

All the attaching works have completed. Check that all the hooking claws are fixed to the specified positions.

– 100 –

Toshiba RAS-10EAVP-E, RAS-B16EKVP-E, RAS-13EAVP-E, RAS-B13EKVP-E, RAS-16EAVP-E User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual